Tuthill KINNEY KD Series User manual

KINNEY®
Rotary Piston Vacuum Pump
KD Series
Models
KD-30
KD-50
OPERATOR’S MANUAL
Manual 1808 Rev B p/n 001808 0000
Tuthill Vacuum & Blower Systems tuthillvacuumblower.com 800.825.6937
WARNING: Do Not Operate Before Reading Manual
Operator’s Manual: Tuthill KINNEY®KD Series Rotary Piston Vacuum Pump
Copyright © 2019 Tuthill Vacuum & Blower Systems
All rights reserved. Product information and specications subject to change.

Disclaimer Statement:
All information, illustrations and specications in this manual are based on the latest information available at
the time of publishing. The illustrations used in this manual are intended as representative reference views only.
Products are under a continous improvement policy. Thus, information, illustrations and/or specications to
explain and or exemplify a product, service or maintenance improvement may be changed at any time without
notice.
Rights Reserved Statement:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic or me-
chanical, including photocopying, recording, taping or information storage and retrieval systems - without the
written permission of Tuthill Vacuum & Blower Systems.
Copyright © 2019 Tuthill Vacuum & Blower Systems
All rights reserved. Product information and specications subject to change.
The employees of Tuthill Vacuum & Blower Systems thank you for your purchase!
Tuthill Vacuum & Blower Systems proudly manufactures
Kinney®vacuum pumps and M-D PneumaticsTM blowers and
vacuum boosters in Springeld, Missouri, USA. We bring
100+ years of engineering experience and solid, hands-
on care to help customers keep their processes running.
Your satisfaction is important to us so please take time to
provide your Tuthill sales representative with performance
feedback. We love to hear from our customers!
Tuthill is a family owned business that was started by James
B. Tuthill in 1892. At that time, Tuthill manufactured com-
mon brick to Chicago construction companies who were
fueling the city’s rapid expansion. Fast forward to today
and Tuthill now serves sustaining, global markets like agri-
culture, chemical, construction, energy, food and beverage,
pharmaceuticals and medical, transportation, and utilities.
While the company has changed in what it manufactures,
one thing remains throughout every Tuthill line of business
– we are a company with HEART. Our slogan is “Pump Your
Heart Into It” and everyday our employees do just that as
they represent the Tuthill brand and dare to make better.
Thank you for making Tuthill Vacuum & Blower Systems
part of your company’s process! FIND OUT MORE AT
TUTHILL.COM
A company with heart
right from the start.

i
Manual 1808 Rev B p/n 001808 0000
Table of Contents
Introduction .................................................................................. 1
Applicable Documentation ................................................................... 1
Scope of Manual................................................................................... 1
Conventions, Safety and Data Plate........................................... 2
Graphic Conventions Used in this Manual............................................ 2
Safety Instruction Tags.......................................................................... 2
Safety Precautions for Rotary Piston Pumps......................................... 3
Data Plate.............................................................................................. 4
Lifting ............................................................................................ 5
Description ................................................................................... 6
General ................................................................................................. 6
Pump Components ............................................................................... 6
Operating Cycle.................................................................................... 8
Sealing and Lubricating........................................................................ 8
Oil Types ............................................................................................... 8
Installation .................................................................................... 9
General ................................................................................................. 9
V-Belt Drive............................................................................................ 9
Direct Drive ......................................................................................... 10
Discharge Piping ................................................................................ 10
Inlet Piping .......................................................................................... 10
Vacuum Gauges ................................................................................. 11
Electrical Connections ........................................................................ 11
Operation .................................................................................... 12
General ............................................................................................... 12
Filling Pump with Oil............................................................................ 12

ii
Table of Contents
Manual 1808 Rev B p/n 001808 0000
Pre-Start Checks................................................................................. 12
Starting................................................................................................ 12
Stopping.............................................................................................. 13
Gas Ballast.......................................................................................... 13
Maintenance ............................................................................... 14
General ............................................................................................... 14
Changing Oil ....................................................................................... 14
V-Belts ................................................................................................. 14
Gear Drive Units.................................................................................. 14
Draining and Refilling Oil .................................................................... 14
Bearing Lubrication............................................................................. 15
Cleaning.............................................................................................. 15
Oil Separator ....................................................................................... 15
Disassembly / Assembly ........................................................... 17
Disassembly........................................................................................ 17
Reassembly......................................................................................... 17
Troubleshooting......................................................................... 19
Starting Troubles or Stalling................................................................ 19
Checking Pump Performance............................................................. 19
Pump Leaks ........................................................................................ 20
Oil Contamination................................................................................ 21
Discharge Valves ................................................................................ 21
Shaft Seal ............................................................................................ 22
Replacement Parts..................................................................... 25
General ............................................................................................... 25
Spare Parts ......................................................................................... 25
KD-30A Exploded View Drawing ........................................................ 26
KD-30A Parts List................................................................................ 27
KD-50B Exploded View Drawing ........................................................ 28
KD-50B Parts List................................................................................ 29
Declaration of Incorporation..................................................... 30
Warranty – Vacuum Products ................................................... 31
Operating Data Form / Product Registration........................... 32

Manual 1808 Rev B p/n 001808 0000 1
CONGRATULATIONS on the purchase of a new
KINNEY®KD Single-Stage, Duplex Rotary Piston
Vacuum Pump from Tuthill Vacuum & Blower
Systems. Please examine the pump for shipping
damage, and if any damage is found, report it
immediately to the carrier. If the pump is to be
installed at a later date, make sure it is stored in a
clean, dry location and rotated regularly. Make sure
covers are kept on all openings. If pump is stored
outdoors, be sure to protect it from weather and
corrosion.
This manual applies to Kinney Vacuum models
KD-30 and KD-50. Be thoroughly familiar with
these instructions before attempting to install,
operate, or repair this unit. Consult Tuthill Vacuum
& Blower Systems when problems arise that
cannot be resolved after reading this manual.
Always include pump nameplate information when
ordering parts or components.
KINNEY KD vacuum pumps are built to exacting
standards and, if properly installed and maintained,
will provide many years of reliable service. Read
and follow every step of these instructions when
installing and maintaining the pump.
CAUTION
!
Read manual before operation or bodily harm
may result. Attention should be given to the
safety related sections of this manual.
OTE:NRecord the pump model and serial
numbers of the machine in the
OPERATING DATA FORM on the inside
back cover of this manual. Use this
identication on any replacement part
orders, or if service or application
assistance is required.
APPLICABLE DOCUMENTATION
The applicable documents associated with this
manual are:
• EN 1012-1:1996 - Compressors and vacuum
pumps - Safety Requirements - Part 2: Vacuum
Pumps
SCOPE OF MANUAL
The scope of this manual includes the following
components as offered by Tuthill Vacuum & Blower
Systems: Rotary Piston Pump.
INTRODUCTION
01

Manual 1808 Rev B p/n 001808 0000
2
GRAPHIC CONVENTIONS USED IN
THIS MANUAL
The following hazard levels are referenced within
this manual:
DANGER
!
Indicates a hazardous situation that, if not
avoided, will result in death or serious injury.
WARNING
!
Indicates a hazardous situation that, if not
avoided, could result in death or serious
injury.
CAUTION
!
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate
injury.
Indicates a situation that can cause damage
to the engine, personal property, and/or
the environment or cause the equipment to
operate improperly.
OTE:NIndicates a procedure, practice, or
condition that should be followed in
order for the equipment to function in the
manner intended.
SAFETY INSTRUCTION TAGS
WARNING
!
Do not operate without belt
guard.
CAUTION
!
Do not valve or restrict pump discharge
opening.
Use oil mist eliminator when operating pump,
ensure adequate ventilation when discharging
indoors.
Refer to manual safety instructions.
The above safety instruction tags were
permanently afxed to your pump prior to
shipment. Do not remove, paint over or
obscure in any manner.
Failure to heed these warnings could result in
serious bodily injury to the personnel operating
and maintaining this equipment.
CONVENTIONS, SAFETY AND DATA PLATE
02

Manual 1808 Rev B p/n 001808 0000 3
02
Conventions, Safety and Data Plate
SAFETY PRECAUTIONS FOR
ROTARY PISTON PUMPS
Please read the following safety information before
operating the vacuum pump.
• Do not operate the pump without the beltguard
properly attached.
• Disconnect the pump from the electrical supply
at the main disconnect before removing the
beltguard. Replace the beltguard before
reconnecting the power supply. Operating the
pump without the beltguard secured in place
exposes people in the vicinity of the pump to risk
from rotating drive parts.
• Do not operate the pump with oxygen-enriched
gas in the suction line, where the proportion
of oxygen exceeds 21%, unless the pump has
been prepared with an inert uid suitable for the
application. Pumping oxygen-enriched gases
with mineral oil or other non-inert uids can
cause an explosion in the pump, resulting in
damage or injury.
• Take precautions to avoid prolonged or
excessive exposure to oil mist or process
materials from the discharge of the pump. Do
not allow the pump to discharge into a closed
room or a room without adequate ventilation.
Always use a discharge oil mist eliminator
unless the pump discharge is vented to the open
air. Venting the outlet of the oil mist eliminator to
the open air is highly recommended.
• Do not restrict the pump discharge line in any
way or place any valves in the discharge line.
The vacuum pump is a compressor and will
generate high pressures without the motor
stalling when operated at low suction pressures.
Excessive pressure buildup could cause
damage or injury.
• Disconnect the pump from the electrical supply
at the main disconnect before dismantling
or servicing the pump. Make sure the pump
is completely reassembled, the beltguard is
replaced, and all drain and ll valve and plugs
are closed before reconnecting the power
supply.
• Accidental starting or operation of the pump
while maintenance is in progress may cause
injury or damage.
• Lift only with the lifting eyebolts supplied with
the pump. Do not lift equipment attached to the
pump with the eyebolts supplied.
• Do not touch hot surfaces on the pump. In
normal operation at low pressures, surface
temperatures will not normally exceed 180°F
(82°C). Prolonged operation at 200 Torr may
cause surface temperatures up to 220°F
(104°C).
• GEAR DRIVES UNITS: During operation,
gear drive units may become sufciently hot to
cause skin burns. Take care to avoid accidental
contact. After extended running, the lubricant in
gear units and lubrication systems may reach
temperature sufcient to cause burns. Allow
equipment to cool before servicing or performing
adjustments.

Manual 1808 Rev B p/n 001808 0000
4
02
Conventions, Safety and Data Plate
DATA PLATE
MODEL NUMBER: The specic model of the blower
SERIAL NUMBER: Unique to each blower
YEAR: Year of manufacture
This manual describes instructions and precautions
to be observed in the handling and maintenance
of Tuthill Vacuum & Blower Systems Kinney
KD Rotary Piston Vacuum Pumps. It is strongly
recommended that those who operate or maintain
the pump read this manual carefully prior to pump
operation, to ensure personal safety and pump life.
WARNING
!
Keep body & clothing away
from machine.
During operation, keep body
and clothing away from inlet
and outlet of the pump.
WARNING
!
Do not operate without guard in
place. Assure that the guards
are in place and secure prior to
operation.
CAUTION
!
Hearing protection is required
while the pump is in operation.
At ultimate pressure noise
levels are 75 dBA, however
due to process or installation
conditions noise levels may be
higher.
CAUTION
!
Do not touch hot surfaces.
Do not touch the vacuum pump
while it is in operation and
assure that the pump is cool
before touching, when not in
operation.

Manual 1808 Rev B p/n 001808 0000 5
LIFTING
03
WARNING
!
The vacuum pump must be handled using
an appropriate device such as a fork truck
or appropriate lifting device. See Table 4-2
on page 7 for approximate weights. Care
should be taken to assure pump does not
overturn during handling and installation.

Manual 1808 Rev B p/n 001808 0000
6
GENERAL
The visual difference between the two pumps is
in the oil separators. Internally, the pistons, cams,
and slide pins of the KD-50 are treated to be able
to tolerate the increased speed. Both pumps are
air-cooled rotary piston type, consisting of two
rotary pistons pumping in parallel. The pumps
attain a low ultimate pressure of less than 10
microns (1 x 10 in. Torr McLeod gauge). The
rugged, simple design ensures dependable service
under the most severe applications without costly
or complicated maintenance. The ruggedness
of the pump is evidenced by all cast-iron rotary
internals, including the cast-iron sleeve bearings.
The external drive shaft bearing is a sealed
grease packed bearing. The mechanical shaft seal
contains viton elastomer, which is suitable for most
chemical as well as high-temperature operations.
PUMP COMPONENTS
All components are easily serviced and no special
tools are required. The reliable, leak-free shaft seal
requires no adjustment or maintenance. The gas
ballast valve regulates the vapor handling capacity
of the pump, decelerates contamination buildup
in the oil, and quiets the discharge valve noise
of the pump. The oil separator of the KD pump is
equipped with a mist eliminator to provide ltering
of the exhaust, thereby resulting in a cleaner pump
area. The pump specications are shown in Table
4-1 and Table 4-2 on page 7.
DESCRIPTION
04

Manual 1808 Rev B p/n 001808 0000 7
04
Description
KD-30 KD-50
Free Air Displacement 33 CFM (56 m3/h) 52 CFM (88 m3/h)
Inlet Connection (NPT) 1-1/2 in. (38 mm) 1-1/2 in. (38 mm)
Discharge Connection (NPT) 1-1/4 in. (32 mm) 1-1/4 in. (32 mm)
Pump Speed (RPM) 571 900
Motor Speed (RPM) 1,725 1,725
Motor Horsepower 1-1/2 in. (38 mm) 2 in. (51 mm)
Table 4-1 – Pump Specifications
KD-30 BELT
DRIVE
KD-30 DIRECT
DRIVE
KD-50 BELT
DRIVE
KD-50 DIRECT
DRIVE
Oil Capacity (Kinney AX) 4 qt (3.8 L) 4 qt (3.8 L) 12 qt (11.4 L) 12 qt (11.4 L)
Weight Complete Pump 200 lb (91 kg) 650 lb (295 kg) 230 lb (104 kg) 650 lb (295 kg)
Height 27 in. (69 mm) 37 in. (94 mm) 32-1/2 in.
(83 mm)
34-1/2 in.
(88 mm)
Width 20-1/2 in.
(52 mm) 18 in. (46 mm) 20-1/2 in. (52 mm) 18 in. (46 mm)
Length 27-7/8 in. (71 cm) 44-1/4 in.
(112 cm) 28-5/8 in. (73 cm) 42-1/4 in. (112 cm)
Typical Noise Level @ 10 Torr < 85 dBA < 85 dBA < 85 dBA < 85 dBA
Table 4-2 – Complete System Specifications
The two rotary pistons pump in parallel and are
driven by two eccentric cams keyed to a shaft. See
Figure 4-1 on page 7.
Figure 4-1 – Operating Cycle

Manual 1808 Rev B p/n 001808 0000
8
04
Description
Each rotary piston is composed of a cylindrical
element that encloses the shaft and a hollow
rectangular extension that moves through a slide
pin. The piston slide pin has openings that are
covered and uncovered as it passes through the
slide pin, allowing gas to enter the cylinder and be
compressed. The ends of the cylinder are enclosed
by an open head, through which the shaft extends,
and a closed head. The shaft has a mechanical
seal on the open head end to prevent leakage
around the shaft. Spring-loaded discharge valves
are located at the discharge side of the pistons. An
oil separator oil mist eliminator is mounted on top
of the pump and connected to the discharge of the
pump. A sight gauge in the oil separator is provided
for checking the oil level. When pumping at low
inlet pressure, the oil level should be in the center
of the sight gauge.
NTE:NThe oil level will change with large
changes in pump inlet pressure.
OPERATING CYCLE
The operating cycle is shown in Figure 4-1 on
page 7. Gas from the system enters the pump
through the inlet, and from there it passes through
the hollow piston-slide and out the slide port into
the space being created between the piston and
cylinder wall. As the piston rotates, this space
increases and more gas is drawn in while at the
same time the gas taken in and trapped. The
previous revolution is on the compression side of
the piston and slide. Here, the gas is compressed
and forced out through the discharge valves along
with a small amount of oil and then into the oil
separator, where the oil is separated from the gas.
The gas is discharged to the atmosphere, and the
oil drains back into the reservoir. The KD pump has
a lter to remove visible fumes from the discharged
gas.
SEALING AND LUBRICATING
The oil ows through the pump by means of
differential pressure between atmosphere and the
pump inlet, and it is drawn into the pump at each
head through the shaft bearings. The cylinder
walls, pistons, and slide pin are lubricated and
sealed against the backow of gas by a lm of
oil that lls the close running clearances. The
cylindrical part of the piston almost touches the
pump cylinder at a line along the length of the
piston, and as the piston continues to rotate, oil
builds up ahead of this line and seals the space
between the piston and cylinder wall. The excess
oil is discharged with the gas and is returned to
the oil reservoir. At low pressures, the air becomes
mixed with the oil and the solution is discharged on
the compression stroke.
OIL TYPES
The ability of the KD-30 and KD-50 pumps to
obtain and hold pressures in the low micron range
depends on the use of the proper sealing and
lubricating oil. AX Vacuum Oil is recommended as
it has characteristics necessary to obtain a dry,
low vapor pressure uid with suitable viscosity.
Other applications such as oxygen pumping
may require changing oil to Fomblin® or other
peruoropolyether (PFPE) where low temperatures
are likely to be encountered. Other special uids
used are polyglycals, uorocarbons, and FDA-
approved lubricants. Consult the factory before
changing from the recommended oil to ensure that
the new uid and present seals are compatible.

Manual 1808 Rev B p/n 001808 0000 9
INSTALLATION
05
GENERAL
Select a pump site with enough room for pump
maintenance and service. Secure the pump to a
level, rigid, support. Spring vibramounts can be
used if sufciently exible connectors are used in
the manifolding.
V-BELT DRIVE
To install the V-belts, loosen the motor mounting
screws and slide the motor toward the pump.
Position the V-belt on the pump with the slack side
on the top of the drive. Move the motor away from
the pump to tighten the drive, and refer to Step 2 to
check the tension of the V-belts. Before attempting
to tension any V-belt drive, it is imperative that the
sheaves be properly aligned. Position the sheaves
so as to allow the belt to be placed in the grooves
rolling them onto the sheaves.
The following tensioning steps can be safely
followed for all belt types, cross-sections, number
of belts per drive, or type of construction:
1. With the belt properly in the groove, adjust the
sheaves until all slack has been taken up.
2. Start the drive and continue to tension the
V-belt(s) until only a slight bow on the slack
side of the drive appears while operating under
load conditions as shown in Figure 5-1 on
page 9.
Figure 5-1 – V-Belt Tensioning
3. After 24 to 48 hours of operation, the belt
will seat itself in the sheave grooves. Further
tensioning is then necessary as described in
Step 2.
Insufcient tensioning is often evidenced by
slipping (squealing) at start-up. Do not be use belt
dressing on V-belts. Sheaves and V-belts should
remain free of oil and grease.
Remove tension from the belt if the drive is to
be inactive for an extended period of time. For
more specic information, consult the drive
manufacturer.

Manual 1808 Rev B p/n 001808 0000
10
05
Installation
DIRECT DRIVE
Mounted the pump on a at and level surface. If
the pump is to be installed outdoors, ensure the
motor, painting, peripheral equipment, parts, etc.,
are suitable for outdoor operation. Allow enough
space around the pump for safe maintenance
work and periodic inspections. This includes, at
a minimum, the ability to access oil ll and drain
locations and to view the oil level sight glass.
The KD series Drive-Drive models are direct driven
by two methods:
• 8 pole (KD50) or 12 pole (KD30) motors
• Gear reducer driven by 2 or 4 pole motor
If the pump was purchased directly from Tuthill,
the coupling has been factory-aligned and tested.
When installing the pump alone to be direct-
coupled to a motor or gear drive, ensure the
coupling alignment meets the manufacturer’s
recommendations to avoid excessive loading of the
pump or motor bearings.
DISCHARGE PIPING
It may be desirable to connect discharge piping
from the oil separator to the outside to dispose
of exhaust gases and vapors. See Figure 5-2 on
page 10. When connecting discharge piping,
place a dropout trap adjacent to the oil separator
to trap the condensate, which would otherwise
drain back into the oil. If the condensate is water,
drain it as necessary to prevent it from owing
back into the reservoir. A exible connector, such
as a rubber hose, at the discharge of the pump
is necessary to make the piping exible and to
provide a convenient disconnect point for servicing.
Turned down the outside end of the discharge line
to prevent entry of precipitation.
Figure 5-2 – Typical Manifold Arrangement
INLET PIPING
Size and design the inlet piping with three
objectives in mind:
• To prevent undue gas ow restriction
• To prevent pump uids from splashing into the
process chamber
• To protect the pump from injection of particulate
matter
Tuthill recommends that the vacuum piping to the
pump inlet be as large in diameter and as short
in length as possible and no smaller in diameter
than the pump inlet. See Figure 5-2 on page
10 for recommended arrangement of vacuum
manifolding.
As with all rotary mechanical pumps, it is
necessary to install a exible member in
the suction manifold of the pump to avoid
alignment problems and to reduce the possibility
of transmitting vibration to and from other
components. Self-supporting, bellows-type, exible
connectors are recommended and are available
from Tuthill Vacuum & Blower. Use a connector be
exible enough to prevent vibration transmission
and yet rigid enough to prevent collapsing under
high vacuum.

Manual 1808 Rev B p/n 001808 0000 11
05
Installation
Before connecting the manifolding to the pump,
pour 1 pint (0.5 L) of oil into the inlet connection to
ensure proper lubrication at initial start-up. When
all inlet connections are made, check that the
pressure of the system is near the pump blank-off
pressure. The demountable joints should be O-ring
sealed or threaded connections made with Teon
sealing tape or other sealing compound. Loctite
567 is available from Tuthill Vacuum & Blower as
a compound for thread sizes up to 1 in. (2.5 cm) in
diameter or Titeseal (Radiator Specialty Company)
for larger thread sizes. Install a vacuum isolation
valve between the system and the pump with a
means for connecting a vacuum gauge on both
sides of the valve. The gauge connections should
face vertically down for self-draining and should be
free from the splash of the pumping action. An air
admittance valve on the pump side of the isolation
valve is recommended. With such an arrangement,
it is possible to check either the system or the pump
for leaks without disconnecting the vacuum piping.
This isolation valve will also allow the system to be
kept under vacuum while the pump is not running
or allow the pump to continue operating while the
system is open to atmospheric pressure.
VACUUM GAUGES
Two general types of vacuum gauges are used for
testing vacuum equipment: total pressure reading
types, such as Thermistor or Thermocouple
gauges, and partial pressure reading McLeod
gauges. The McLeod gauge indicates the partial
pressure of a gas and does not indicate the
component of pressure due to condensable vapors
such as water vapor. Partial vapor pressure has
little effect on the McLeod gauge readings until it
becomes quite high. Therefore, a McLeod gauge
is most useful in conrming pump performance
and for determining the absence or presence of
real leaks. Thermistor or thermocouple gauges
are preferable for leak checking, and when
used in conjunction with a McLeod gauge the
contamination level can be determined.
A high thermistor or thermocouple gauge reading
may indicate that the pump is contaminated, that
it leaks, or both. A high McLeod gauge reading
means that a real leak is present.
ELECTRICAL CONNECTIONS
WARNING
!
Disconnect pump from source of electrical
power prior to making repairs or adjustments
to any electric component of the unit.
Check the operating voltage of the motor
by comparing the lead connections with the
markings on the motor. Wire to the proper power
source through necessary switching and safety
equipment. Connect the solenoid valve so that it is
energized when the motor is started. The valve is
normally closed and will open when energized.
The motor must turn in the direction of the arrow
cast on the pump. If the motor turns in the wrong
direction, reverse any two of the three wires
leading from the motor to the power source.
Standard pumps are designed to run clockwise
when facing the pump pulley.

Manual 1808 Rev B p/n 001808 0000
12
WARNING
!
The belt guard must be properly secured
to the pump at all times while the pump is
running.
When operating the pump in an enclosed
area it is necessary, for health reasons, to
have the area well ventilated. If ventilation is
not adequate, the pump discharge should be
ltered or piped to open air.
Do not block or restrict the ow of gas from
the pump discharge. Back pressure within the
pump could cause severe damage.
GENERAL
Each pump has been thoroughly tested and is
ready for operation as soon as it is installed and
lled with oil. If the vacuum system is free of leaks,
including the connections to the pump, the ultimate
system pressure should be close to the pressure
obtained with the pump inlet closed off.
FILLING PUMP WITH OIL
When installing the pump, pour 1 pint (0.5 L) of
oil into the pump inlet before connecting the inlet
piping. Thereafter, pour the total required quantity
of oil into the oil separator.
PRE-START CHECKS
Performed the following pre-start checks if
maximum pumping conditions are required.
1. Check that the suction lines are tight and
absolutely free of all foreign matter.
2. Add oil as necessary to bring the oil level
midway on the sight gauge.
3. Check that the pump can be turned over by
hand without mechanical interference. With the
inlet at atmospheric pressure, turn the pump
and note that more turning force is required
when the pump discharges. This indicates that
the discharge valves are seating properly.
4. Check the V-belt tension as shown in Figure
5-1 on page 9.
5. Check that direction of rotation is correct.
STARTING
Perform the pre-start checks, and do not start the
pump until the oil temperature is above 40°F (4°C).
1. Depress the motor start button and allow the
pump 10 minutes to warm up, at blank-off,
before starting process work.
2. Check that the oil solenoid valve is energized
and open, allowing the oil level to drop in the
sight gauge.
OPERATION
06

Manual 1808 Rev B p/n 001808 0000 13
06
Operation
The oil level will change with the pumping
pressure. When the pump is rst started, the oil will
rise. As the inlet pressure is reduced, the oil level
will drop and should stabilize midway on the sight
gauge when the pump pressure approximates
blank-off.
STOPPING
1. If a vacuum valve is provided between the
pump and the process equipment, place this
valve in the CLOSED position.
2. Turn off the power to the pump motor, and
vent the pump to atmosphere. The gas ballast
valve can be used for this purpose if a vent
valve has not been provided. Venting the pump
prevents ooding, which makes starting the
pump difcult. Do not use the gas ballast valve
for venting connected (process) volumes. Use
the gas ballast valve only for venting the pump
casing and a short length of manifold.
GAS BALLAST
Gas ballast is an operating mechanism that is used
to prevent the condensation of vapor in a vacuum
pump. Vapor present in the gas being pumped can
condense during the vacuum pump compression
cycle and mix with the oil. As the oil is circulated
through the pump, the condensate is carried
with the oil and allowed to re-evaporate, causing
poor pump performance and making frequent oil
changes necessary. By using gas ballast, most
vapors can be passed through a vacuum pump
without condensing and then discharged with
the pump exhaust. Unless the lowest possible
pressure is necessary, operate the pump with gas
ballast.
In addition to preventing vapor condensation,
the use of gas ballast also reduces discharge
valve noise to a low level. It is generally possible
to eliminate valve noise with a small gas ballast
ow that does not seriously increase the ultimate
pressure. If the resulting pressure is tolerable, this
method of operation is preferred since it also helps
to keep the oil clean. The setting of the gas ballast
valve is best determined by trial and error because
the amount of condensable vapor as well as the
system operating conditions vary with different
processes. The motor power consumption and
the ultimate pressure will rise in proportion to the
increase in gas ballast ow.
Gas ballast can be used in the following two ways:
1. Continuous gas ballast can be regulated
to ow into the pump while processing. To
regulate the gas ballast valve, while dead
ended, slowly open the valve until the pressure
is slightly below that needed for process work.
Operate the pump at this setting to keep oil
contamination to a minimum.
2. Intermittent gas ballast can be used when
pressure requirements do not permit the use
of continuous gas ballast. Running the pump
overnight with full gas ballast is recommended
for cleaning the oil of contamination. The
condition of the oil can be estimated by
observing the pump blank-off pressure with
the gas ballast valve closed. Run the pump
with the gas ballast valve open for a timed
period (15 to 20 minutes) and observe the
blank-off pressure change. When there is no
further change in pressure, the oil is clean.
This pressure change vs. time can be used to
estimate the required time to clean the oil.

Manual 1808 Rev B p/n 001808 0000
14
MAINTENANCE
07
GENERAL
Check the oil level daily for the rst week of
operation and weekly thereafter. The oil level
should be about midway on the sight gauge when
operating at low inlet pressures. However, the oil
level rises as the inlet pressure goes up. A good
check of the oil passage circuit is to change the
inlet pressure or open the gas ballast valve and
watch the oil level, which should rise as the inlet
pressure goes up. Check the condition of the
oil periodically by draining a small quantity into
a clean container and visually inspecting it for
solid or liquid contaminants. Change the oil when
contamination is present after making full use of
gas ballast to clean the oil. Change the oil when
the pump has logged 750 hours of operating time
or more often if an inspection of the oil dictates.
CHANGING OIL
Run the pump until the oil is warm (>100°F [38°C]),
then open the G.B. valve for a 1 – 2 minutes.
Then, stop the pump and open the drains in both
the pump and reservoir. Fill the pump with oil as
directed under Filling Pump with Oil on page
12. If the pump oil is badly contaminated,
additional changes may be necessary with a 10
minute operating period between changes to check
the pump blank-off pressure. Several oil changes
may be necessary under extreme conditions.
V-BELTS
To change the V-belt, loosen the motor mounting
screws and slide the motor toward the pump until
the old belt can easily be slipped from the pulleys.
The motor must be close enough to the pump to
enable the new belt to be slipped onto the pulleys
without rolling or stretching. When the belts are
in place, pull the slack of both belts to the same
point and tension the belts as shown in Figure
5-2 on page 10. Belts should not slip under full
load, that is, when starting, if the proper tension
is maintained. However, too much tension will
place an undue strain on the shaft bearings. Adjust
the tension on new belts after 24 to 48 hours of
operation.
GEAR DRIVE UNITS
NOT:NOhe gear drive unit comes with an initial
charge of oil. Check the oil level every
3,000 hours or 6 months, whichever is
sooner. Recommended oil is Grade 6T.
DRAINING AND REFILLING OIL
Prior to Any Maintenance Operations
1. De-energize the drive and secure against it
unintentionally switching on.
2. Wait until the pump has cooled down. A hot
pump has skin burn and pressure buildup
hazards.

Manual 1808 Rev B p/n 001808 0000 15
07
Maintenance
Oil Plugs / Ventilator
1. Prior to removing plugs, ensure that the pump
has cooled sufciently so that oil will not burn.
2. Remove ventilator plug prior to removing level
and/or drain plug.
WARNING
!
Do not stand over ventilator plug while
removing as pressure build up behind valved
ventilator may cause it to eject when removed.
3. Place a container under the oil drain plug to be
removed.
NOT:NIt is recommended that the oil should
be slightly warm (104°F – 122°F [40°C –
50°C]) when drained. Cooler oil will be
more difcult to drain correctly.
4. Rell oil through the ventilator position.
5. Ret all plugs after lling.
6. Clean away oil spillage.
BEARING LUBRICATION
Where re-greasing points are provided, add 2
shots monthly of NLGI 2 grade grease.
CLEANING
1. With the drive stationary, periodically clean any
dirt or dust from the gear unit and the electric
motor cooling ns and fan guard to aid cooling.
2. Ensure dust buildup does not exceed 0.2 in.
(5 mm).
OIL SEPARATOR
All KD-30 and KD-50 blowers built since October
1984 are tted with oil mist eliminators in the oil
separator. If the oil separator has a lter, it will be
necessary to periodically replace the lter element
and remove any sludge accumulation.
The frequency of this is dependent upon the
following conditions:
• Visual inspection shows the element to be
blocked by foreign matter. A back pressure
through the lter element exceeding 6 PSlG
indicates that the lter element is unduly
restricting the gas ow and should be changed.
• Motor current exceeds manufacturer’s
specications.
• A ruptured element or the gaskets are not
sealed, allowing mist to be discharged.
The oil separator on KD-30A and KD-50B pumps
is equipped with an oil drain-back device to return
oil to the reservoir that has penetrated the lter
element. The check-type drain-back closes to
prevent the exhaust gas from bypassing the lter
when the inlet pressure is high and opens to
allow the oil to drain back as the inlet pressure
is reduced. If the pump is operated at high inlet
pressures, over 5 Torr, for time periods exceeding
several hours, no drain-back can occur and lter
efciency is reduced. Under such conditions,
isolate the pump from the system with the main
isolation valve, and run at blank-off pressure for
15 – 30 minutes to allow the oil to drain back. If
the pump is always operated with lengthy high
pressure, then install an external oil return line as
follows.
A return line can be installed to return oil that
collects in the lter area back to the pump.
The successful operation of this arrangement
is dependent upon having the oil return to the
pump at a point that is compatible with the pump
operating pressure level. See Figure 7-1 on page
16. Generally, oil must be returned to a low
pressure point. The oil separator has an oil return
valve that allows oil ow back when operating at
pressures below 5 Torr.

Manual 1808 Rev B p/n 001808 0000
16
07
Maintenance
Figure 7-1 – Return Line
One of the following two areas can be selected for
the oil to return to the pump when operating above
5 Torr:
• If the pump operating range is between 5 and
150 Torr, the returning oil should enter the pump
through the gas ballast valve, in which case the
valve must be left open.
• When the operating range is above 150 Torr,
the returning oil should enter the pump at the
suction port area.
An alternative to the above arrangements is
to drain the collected oil into a container and
periodically return it to the pump through the oil
ll. This arrangement is preferred if the collected
oil contains a substantial amount of water. In this
event, leave the oil to stand until the oil and water
separate, at which time the water will be decanted,
before returning the oil to the pump. With this
arrangement, take special care to keep the oil
clean.