TKM K Series Manuale utente

K SERIES

PLUNGER

PUMP

KP Pump Installation and Operating

Instructions Manual

TKM LLC

1059 Triad Court, Suite 1

Marietta, GA, USA, 30062

+1 (770) 943-4922

TKM K Series Metering Pumps Operation Manual 
 
KP OM v.1.8 Copyright © 2018 TKM LLC All Rights Reserved 2 
Table of Contents 
INTRODUCTION TO TKM K SERIES METERING PUMPS ................................................................ 5 
1 DESCRIPTION OF TERMS................................................................................................................................................ 5 
2 GENERAL INFORMATION................................................................................................................................................ 5 
SAFETY INSTRUCTIONS AND GUIDELINES..................................................................................... 6 
1 QUALIFIED PERSONNEL AND TRAINING ...................................................................................................................... 6 
2 SAFETY PRECAUTIONS DURING MAINTENANCE,SERVICING,AND INSTALLATION................................................. 6 
3 NEGLECTING THE SAFETY INSTRUCTIONS.................................................................................................................... 7 
4 IMPORTANCE OF TKM AUTHORIZED SPARE PARTS................................................................................................... 7 
5 INTENDED USE FOR THE TKM PUMP........................................................................................................................... 7 
6 PERSONAL PROTECTION EQUIPMENT FOR INSTALLATION AND MAINTENANCE.................................................... 8 
MANUFACTURER’S WARRANTY...................................................................................................... 8 
GENERAL DESCRIPTION OF TKM K SERIES PLUNGER PUMP ....................................................... 9 
1 KP PLUNGER PUMP MODELS ....................................................................................................................................... 9 
1.1 The Standard KP Pump....................................................................................................................................... 9 
1.2 The High-Pressure KP Pump ...........................................................................................................................10 
1.3 The Low-Flow KP Pump....................................................................................................................................10 
1.4 The High Viscosity KP Pump ...........................................................................................................................10 
2 KP PLUNGER PUMP STANDARD FEATURES...............................................................................................................10 
RECEIVING AND STORING A TKM PUMP ..................................................................................... 10 
1 RECEIVING INSPECTION................................................................................................................................................11 
2 STORING A TKM PUMP...............................................................................................................................................11 
TECHNICAL DATA............................................................................................................................ 12 
1 SPECIFICATIONS ............................................................................................................................................................12 
2 KP PUMP DIMENSIONS ...............................................................................................................................................13 
3 TEMPERATURE...............................................................................................................................................................13 
4 NOISE LEVELS................................................................................................................................................................13 
5 PUMP NAME PLATE NOTATION .................................................................................................................................14 
6 KP STANDARD COMPONENTS....................................................................................................................................15 
7 KP GEAR OIL.................................................................................................................................................................16 
INSTALLATION ................................................................................................................................ 16 
1 MOUNTING A TKM PUMP ..........................................................................................................................................16 
2 CONNECTING THE SUCTION PIPING...........................................................................................................................17 
2.1 Suction Line Filters..............................................................................................................................................19 
3 CONNECTING THE DISCHARGE PIPING ......................................................................................................................20 
3.1 Pressure Relief Valve ..........................................................................................................................................20 
3.2 Pulsation Dampener...........................................................................................................................................21 
3.3 Back Pressure Valve or Anti-Siphoning Mechanism................................................................................21 
4 RECOMMENDED CONFIGURATION FOR TKM KP PUMP SYSTEM ..........................................................................23 
5 FLUSHING THE LIQUID END.........................................................................................................................................23 

TKM K Series Metering Pumps Operation Manual 
 
KP OM v.1.8 Copyright © 2018 TKM LLC All Rights Reserved 3 
8. PUMP COMPONENTS ..................................................................................................................... 24 
8.1 THE GEAR BOX..............................................................................................................................................................24 
8.2 STROKE LENGTH ADJUSTMENT...................................................................................................................................24 
8.2.1 Adjusting the Stroke Position ..........................................................................................................................25 
8.3 THE LIQUID END ...........................................................................................................................................................25 
8.3.1 The Check Valves.................................................................................................................................................26 
8.3.2 The Plunger and Packing..................................................................................................................................27 
8.3.3 Replacement Parts and Repair Kits...............................................................................................................27 
8.3.4 Repair Kit Contents.............................................................................................................................................28 
8.4 THE ELECTRIC MOTOR .................................................................................................................................................30 
8.4.1 Configuring the Electric Motor........................................................................................................................30 
9. STARTUP .......................................................................................................................................... 31 
9.1 STARTING A TKM PUMP .............................................................................................................................................31 
10. SERVICING A TKM KP PUMP...................................................................................................... 32 
10.1 REBUILDING THE CHECK VALVES ................................................................................................................................33 
10.1.1 Removing the Guides and Seats................................................................................................................33 
10.1.2 Replacing the Guides and Seats ................................................................................................................33 
10.2 REPLACING THE STANDARD KP PLUNGER PACKING................................................................................................34 
10.3 REPLACING THE HIGH-PRESSURE PLUNGER PACKING.............................................................................................36 
10.4 CHANGING THE GEAR OIL...........................................................................................................................................38 
10.5 TROUBLESHOOTING THE TKM KP PUMP..................................................................................................................39 
10.6 RETURNING THE TKM PUMP FOR REPAIRS...............................................................................................................42 
10.6.1 Preparing the TKM Pump for Returns .....................................................................................................42 
10.6.2 RMA for TKM Pump Return.........................................................................................................................43 
11. CONTACTING TKM LLC............................................................................................................... 43 
 
 
 
Table of Figures 
 
Figure 1 - Avoid irregular piping when connecting the suction line .....................................................18 
Figure 2 - Avoid debris from bottom of reservoir tank ..............................................................................18 
Figure 3 - Always run piping through walls or barriers ..............................................................................18 
Figure 4 - Avoid rounded tubing in suction line to prevent air in suction line..................................19 
Figure 5 - Correctly integrating a Y-strainer on the suction line.............................................................19 
Figure 6 - Using a foot valve with a strainer when suction line runs into reservoir tank ...............20 
Figure 7 - PRV and recycling line ........................................................................................................................20 
Figure 8 - Pulsation dampener and back pressure valve ...........................................................................21 
Figure 9 - Using a back pressure valve to avoid unwanted siphoning .................................................22 

TKM K Series Metering Pumps Operation Manual

Figure 10 - Recommended configuration for TKM Pump system ..........................................................23

Figure 11- The adjustment knob.........................................................................................................................25

Figure 12 - Correct orientation for discharge valve .....................................................................................34

Figure 13 - Correct orientation for suction valve ..........................................................................................34

Figure 14 - KP Standard Pump Liquid End ......................................................................................................36

Figure 15 - KP High-Pressure Pump Liquid End ............................................................................................38

Figure 16 - Oil plug locations...............................................................................................................................38

This Operating Instructions Manual and all the technical information provided is

property of TKM LLC. This document is protected by U.S. and International copyright

laws. Reproduction, modification, or distribution of the manual without written

permission from TKM LLC is prohibited.

TKM K Series Metering Pumps Operation Manual

1. Introduction to TKM K Series Metering Pumps

This instruction manual is to provide the end user with an extensive understanding of TKM

Metering Pumps. The information provided in these instructions includes important guidelines

for the safe and successful installation, operation, and maintenance of TKM K Series Plunger

Metering Pumps.

The instructions and additional information outlined in this document must be integrated into

the current rules and regulations in the location of installation. The instructions in this manual

DO NOT replace any company or plant regulations or requirements which have been issued for

safety purposes.

1.1 Description of Terms

To prevent ambiguity and possible misinterpretation of information, the following technical

description of users and personnel have been defined and assigned a common term, which will

be referred to hereafter. The following terms are only a few of the most common terms used

in the entire manual.

•Manufacturer –Refers to TKM LLC

•End User –Refers to the company, whether through a distributor or directly, that

purchases the TKM Metering Pump for their own private use

•Distributor –A third-party company acting between the Manufacturer and the End User

that focuses exclusively on purchasing TKM Pumps for redistribution

•Representative –A third-party company acting on behalf of TKM LLC. These

companies can repair, service, and offer advice to End Users

•Qualified Personnel –Pump operators, technicians, installers, or maintenance staff who

have undergone the appropriate training necessary to handle TKM Metering Pumps

1.2 General Information

The following instruction manual covers the operation, maintenance, and storage of TKM

Metering Pumps. Correctly following the guidelines presented in this manual will help to:

•Avoid dangers to company personnel, machinery, and the working environment.

•Ensure the longevity of the TKM Metering Pump and the performance of the system.

•Reduce the need for repairs due to mishandling the product.

TKM Metering Pumps are intended for operation in industrial areas and thus are not

considered retail products. The End User must take corresponding accident prevention

TKM K Series Metering Pumps Operation Manual

measures to protect Qualified Personnel from danger while operating, repairing, and handling

TKM products.

This document contains information intended for Qualified Personnel

only. Carefully read the instructions in this manual before using TKM

Metering Pumps. Please keep these instructions for future use.

TKM LLC reserves the right to update or modify the design, features, and components of KP

Pumps. The information contained in this instruction manual is thus subject to change without

notice.

This document and all the technical information provided is property of TKM LLC.

Unauthorized reproduction, modification, or distribution without written consent from

TKM LLC is punishable by law.

2. Safety Instructions and Guidelines

The following safety instructions will assist Qualified Personnel with handling the TKM

Metering Pump in a safe manner.

2.1 Qualified Personnel and Training

The personnel for operation, maintenance, inspection, and installation must be qualified for

their tasks. The End User must clearly define the responsibilities of personnel and organize

their supervision.

The End User is solely responsible for the appropriate training of company personnel and for

assuring that personnel are qualified for the needed work. It is never appropriate nor

acceptable for untrained personnel to handle any TKM product.

In the case that the End User requires the appropriate training for company staff, the

Manufacturer, Distributor, or Representative can provide the necessary training services.

2.2 Safety Precautions during Maintenance, Servicing, and Installation

It is the End User’s responsibility to ensure that only Qualified Personnel who have read and

understood the operating instructions for TKM Metering Pumps are allowed to service the TKM

equipment.

Only TKM spare parts should be used to repair valves or other parts of the TKM Pump.

TKM K Series Metering Pumps Operation Manual

When servicing the connections on the TKM Pump, always confirm

that the connections are not under any pressure. Servicing a TKM

Pump under pressure may result in injury to staff and damage to

equipment.

2.3 Neglecting the Safety Instructions

Neglecting the safety instructions may cause danger to company personnel, environmental

hazards, and damage to the TKM Metering Pump or other TKM products.

Dangers resulting from safety negligence may include:

•Product failure

•Bodily harm from mechanical or chemical malfunctions

•Environmental hazards from chemical leaks and pipeline bursts

2.4 Importance of TKM Authorized Spare Parts

Modification of the TKM Pump is not permitted. Repair of the TKM Pump Liquid End is only

permitted after authorization from TKM LLC. Only genuine spare parts approved by TKM may

be used to service the pump. The use of non-TKM replacement parts will immediately

terminate the warranty. See section 3. Manufacturer’s Warranty for more information.

TKM authorized parts are essential for the safe performance of the TKM Pump. Using any parts

unauthorized by TKM LLC may result in serious injury to staff or damage to the TKM Pump.

2.5 Intended Use for the TKM Pump

The TKM Metering Pump or system is only to be used in accordance with the product

description. The End User must honor the specified working conditions of the pump stated in

section 6. Technical Data:

•Liquid End material

•Working pressure of the pump

•Appropriate atmospheric temperature

•Appropriate motor voltage and power

If the TKM Pump is to be used for other applications not previously discussed with TKM LLC,

the End User must consult with TKM before initiating the new process.

TKM K Series Metering Pumps Operation Manual

2.6 Personal Protection Equipment for Installation and Maintenance

The End User is solely responsible for providing their Qualified Personnel with the appropriate

personal protection equipment (PPE) necessary for safely installing and servicing TKM Metering

Pumps.

When servicing the TKM Pump, always adhere to the safety regulations needed for the

pumped chemical.

3. Manufacturer’s Warranty

TKM Metering Pumps, as well as other TKM products, are under a manufacturer’s warranty for

a period of two years (24 months) from the Manufacturer’s shipping date. The warranty covers

replacement, free of charge, of any defective components deemed unsuitable by the TKM

technical office.

This warranty is not valid in the following cases:

•Components subject to normal wear, i.e.:

oValve assemblies

oO-rings, seals, gaskets included in valve assemblies

oPlunger packing

oBearings

•Using unauthorized replacement parts for the TKM Pump

•If the installation or use do not meet the technical conditions of the sale confirmation

•Improper installation of the TKM Pump or not following the installation instructions

(refer to section 7. Installation for full installation procedures)

•Disassembling the TKM Pump

•Tampering with the TKM Pump

•If the End User sells the pump to another party

•Faulty or careless handling i.e. dropping the TKM Pump

The TKM Pump should only be serviced for routine maintenance of

the Liquid End and valve components. DO NOT attempt to repair a

TKM Pump under warranty, and DO NOT attempt to disassemble a

TKM Pump under warranty if the TKM Pump is malfunctioning from

any component other than the Liquid End.

TKM K Series Metering Pumps Operation Manual

Disregarding this notice will result in immediate termination of the manufacturer’s

warranty.

TKM LLC reserves the full right to determine the warranty coverage of a defective TKM

Metering Pump or TKM product. All obligations and liabilities under this warranty are limited

to repairing the TKM Pump, replacing the TKM Pump, or refunding the original purchaser, who

may be the End User or the Distributor, but not both, up to the full purchase price. TKM LLC

shall not be held responsible for any removal or replacement cost, or any additional

consequential damages.

4. General Description of TKM K Series Plunger Pump

The K Series Plunger Metering Pump is a mechanically actuated spring return pump, which falls

into the category of controlled volume alternative displacement pumps.

The KP Pumps include three variations: standard, high pressure, and high viscosity. The

technical data provided in this instruction manual is equally applicable (unless otherwise noted)

for any KP model pump.

KP Pumps are characterized by a plunger Liquid End, which has been engineered to operate in

constant low pressure or high pressure, and in low flow applications while maintaining a

continuous discharge flow.

4.1 KP Plunger Pump Models

The TKM KP Plunger Metering Pump exists in four distinct models, which are described in the

sections below. Each model is designed for a specific application depending on the

requirements provided by the End User.

4.1.1 The Standard KP Pump

The Standard KP Pump is designed and manufactured for use with non-aggressive chemicals.

This pump is built to withstand a maximum pressure of 600 PSI (40 BAR). Fitted with a SAF

2205 duplex steel plunger, and PTFE Chevron Packing, the KP Pump is easy to service and

inexpensive to repair.

The Liquid End and the check valves are made entirely of 316L stainless steel.

TKM K Series Metering Pumps Operation Manual

4.1.2 The High-Pressure KP Pump

The High-Pressure KP Plunger Pump (KP HP) is designed for applications reaching a working

pressure of 1500 PSI (100 BAR). Fitted with a SAF 2205 duplex steel plunger and braided ring

packing composed of PTFE and Kevlar, the High-Pressure KP Pump is manufactured for the

toughest applications where a constant high pressure has to be maintained.

4.1.3 The Low-Flow KP Pump

The Low-Flow KP Plunger Pump (KPL) is used for applications that require consistently low

flows at high pressures. With flowrates ranging from .14 GPH (.5 LPH) to .41 GPH (1.6 LPH), the

KPL is designed for extremely accurate dosing.

Being a KP HP variant, the KPL Pump is fitted with a SAF 2205 duplex steel plunger, and PTFE

and Kevlar packing. The KPL can reach a maximum working pressure of 1500 PSI (100 BAR).

4.1.4 The High Viscosity KP Pump

The High Viscosity KP Plunger Pump (KP HV) is fitted with a Single Valve system and

engineered for pumping fluids with a viscosity of up to 55,000 centipoises. The KP HV can

reach a maximum working pressure of 600 PSI (40 BAR).

4.2 KP Plunger Pump Standard Features

Every KP Plunger Pump is shipped from TKM LLC with the following technical features:

•Anodized cast aluminum housing, yoke, and motor flange

•Powder coated aluminum castings in a deep red color (other colors available upon

request)

•Stainless steel Liquid End

•Stainless steel check valves

•Stainless steel hardware

5. Receiving and Storing a TKM Pump

All TKM Metering Pumps and TKM products are shipped from TKM LLC in excellent condition

after undergoing thorough testing. TKM LLC carefully assembles each pump to the specified

needs of the End User. The pump should only be used for the application intended and agreed

to with TKM LLC.

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