Tuthill KINNEY KT Series User manual

KINNEY®
Single Stage, Triplex Rotary Piston Pump
KT™ SERIES
Models
KT150 KT300 KT500 KT850
OPERATOR’S MANUAL
Manual 1843 1115 ENG
Tuthill Vacuum & Blower Systems tuthillvacuumblower.com 800.825.6937
WARNING: Do Not Operate Before Reading Manual
Operator’s Manual: Tuthill KT™ Series Single Stage, Triplex Rotary Piston Pump

2
TABLE OF CONTENTS
SECTION PAGE
1. INTRODUCTION 3
1.1 APPLICABLE DOCUMENTATION 3
1.2 SCOPE OF MANUAL 3
2. CONVENTIONS AND DATA PLATE 3
2.1 GRAPHIC CONVENTIONS IN THIS MANUAL 3
2.2 DATA PLATE 4
3. LIFTING 5
4. DESCRIPTION 5
4.1 PRINCIPLE OF OPERATION 6
4.2 SPECIFICATIONS 7
4.3 MATERIALS OF CONSTRUCTION 7
5. INSTALLATION 8
5.1 GENERAL 8
5.2 LUBRICATION 9
5.2.1 HAZARDS ASSOCIATED WITH BREAKDOWN OR IGNITION OF LUBRICATION 9
5.2.2 FILLING THE PUMP WITH OIL 10
5.3 LOCATION 10
5.3.1 FOUNDATION 10
5.3.2 INSTALLING THE VIBRAMOUNTS 10
5.4 PIPING CONNECTIONS 11
5.4.1 MAIN PIPING 11
SUCTION MANIFOLDING 11
PROPER VENTING 12
DISCHARGE MANIFOLDING 12
5.4.2 HAZARDS ASSOCIATED WITH HAZARDOUS PROCESS FLUIDS 13
5.4.3 COOLING WATER 13
5.5 VACUUM GAUGES 14
6. OPERATION 14
6.1 GENERAL 14
6.1.1 ELECTRICAL CONNECTIONS 15
6.2 PRE-START CHECKS 15
6.3 PUMP WARM UP 16
6.4 PUMP SHUTDOWN 16
6.5 HANDLING LARGE QUANTITIES OF WATER 16
6.6 GAS BALLAST 17
6.7 STALLING 17
6.8 PUMP LEAKS 17
6.8.1 CHECKING PUMP PERFORMANCE 18
6.8.2 CHECKING PROCESS EQUIPMENT 18
7. MAINTENANCE 19
7.1 GENERAL 19
7.2 PERIODIC MAINTENANCE 19
7.2.1 CHANGING THE OIL 19
7.2.2 OIL CONTAMINATION 20
7.3 REPLACEMENT PARTS 20
7.3.1 RECOMMENDED OIL 21
7.4 FACTORY SERVICE AND REPAIR 21
8. REPAIR INSTRUCTIONS 22
8.1 GENERAL 22
DISCHARGING VALVES 22
8.2 SHAFT SEAL ASSEMBLY 23
8.3 V-BELT DRIVE 24
8.4 DISASSEMBLY 24
8.5 ASSEMBLY 25
9. TROUBLESHOOTING 27
10. KT SERIES PART NUMBER DESIGNATIONS 28
11. PARTS LISTS AND ASSEMBLY DRAWINGS 30
12. WARRANTY – VACUUM PRODUCTS 38
13. OPERATING DATA FORM / PRODUCT REGISTRATION 39

3
1. INTRODUCTION
CONGRATULATIONS on your purchase of a new KINNEY®KT™ Single-Stage, Tri-plex 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 KT-150, KT-300, KT-500 and KT-850. You should 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 KT vacuum pumps are built to exacting standards and if properly installed and maintained will
provide many years of reliable service. We urge you to take time to read and follow every step of these
instructions when installing and maintaining your pump. We have tried to make these instructions as
straightforward as possible. We realize getting any new piece of equipment up and running in as little time
as possible is imperative to production.
CAUTION
Read manual before operation or bodily harm may result. Attention should
be given to the safety related sections of this manual.
NOTE
Record the model and serial numbers of your machine in the OPERATING
DATA form on the inside back cover of this manual. You will save time and
expense by including this reference identication on any replacement part
orders, or if you require service or application assistance.
1.1 APPLICABLE DOCUMENTATION
The applicable documents associated with this manual are:
• EN 1012-1:1996 - Compressors and vacuum pumps - Safety Requirements - Part 2: Vacuum Pumps
1.2 SCOPE OF MANUAL
The scope of this manual includes the following components as offered by Tuthill Vacuum & Blower Systems:
Rotary Piston Pump
2. CONVENTIONS AND DATA PLATE
2.1 GRAPHIC CONVENTIONS IN THIS MANUAL
This manual is the result of a risk assessment according the applicable documents referenced in section
1.1. The following are hazard levels are referenced within this manual:
DANGER
Indicates an immediate hazardous situation which, if not avoided, will result
in death or serious injury.

4
WARNING
Indicates that a physical injury or damage to health or property, if not
avoided, could occur.
CAUTION
Indicates that a potential hazard may occur which, if not avoided, could
result in minor or moderate injury.
NOTE
Indicates a statement of information which, if not avoided, could cause
damage to the product.
CAUTION
Read manual before operation or bodily harm may result. Attention should
be given to the safety related sections of this manual.
2.2 DATA PLATE
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.
WARNINGWARNING CAUTION CAUTION
http://www.tuthill.com
Hearing protection
re
q
uired.
Do not touch hot
surfaces.
ASUehtniedaM7396-528)008(
READ INSTRUCTION MANUAL BEFORE OPERATION OR BODILY HARM MAY RESULT
Keep body & clothing away
from machine openings.
Do not operate without
g
uards in
p
lace.
REBMUNLAIRESREBMUNLEDOM
Tuthill Vacuum & Blower Systems
4840 West Kearney Street
Springfield, Missouri USA 65803
YEARMAWP
MAX RPM

5
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.
MODEL NUMBER: This identies the specic model of the pump.
SERIAL NUMBER: Each pump has a unique serial number. This number is to be used with any
service issues and with any contact with the manufacturer.
YEAR: This states the year that the pump was manufactured.
MAX RPM: This states the maximum RPM that the pump can be operated.
This instruction manual describes instructions and precautions to be observed in the handling and
maintenance of Tuthill Vacuum & Blower Systems Kinney®KT™ Single-Stage, Tri-plex 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.
3. LIFTING
WARNING
The vacuum pump must be handled using an appropriate device such
as a fork truck or appropriate lifting device. See Table 1 for approximate
weights. Care should be taken to assure pump does not over-turn during
handling and installation.
4. DESCRIPTION
The KT-Series pumps covered herein have an oil circulating pump to provide adequate lubrication at all
pressures including atmosphere. The vacuum pump has three cams and pistons pumping in parallel, driven
by a common shaft. The cams are positioned on the shaft so as to dynamically balance moving parts. This
balancing technique applied to the Rotary Piston Principle was developed by Tuthill Vacuum & Blower
Systems and virtually eliminated vibration.
Figure 1 shows a cross section of the pump with the pistons being driven by the cams and revolving within
the cylinder.

6
4.1 PRINCIPLE OF OPERATION
Gas is drawn into the pump through
a common inlet, channeled to the
three piston slides and into the
space behind the pistons as they
rotate. The gas ahead of the pistons
is compressed and forced out the
discharge valves. As the gas is
forced through the pump, sealing
oil is mixed with the discharged
gas and the discharged mixture
is channeled into the separator,
which is located in the reservoir,
and there the gas is separated from
the oil. Sealing and lubricating oil
is provided by the oil pump which
is mounted on the non-drive head
and driven by direct coupling to
the vacuum pump drive shaft. The
oil pump provides forced feed oil
circulation at all operating pressures
including atmosphere.
All models have a channeled drive
shaft with an opening at each cam
to distribute oil through the pump.
Oil is taken from the reservoir at
a point some distance above the
reservoir bottom. This provides
an area for impurities to collect for
draining.
1.
KEY
AIR/OIL SEPARATOR
2. OIL LEVEL
3. CONNECTION FOR OPTIONAL TEMPERATURE SWITCH
4. CONNECTION FOR TEMPERATURE GAUGE
5. CONNECTION FOR “SCUM” TAKE-OFF
6. PUMP INLET
7. SLIDE PIN
8. WATER COOLING JACKET
9. (FAR SIDE) COOLING JACKET DRAIN (1 OF 2)
10. VIBRAMOUNTS
11. DISCHARGE VALVE
12. GAS BALLAST VALVE
13. OIL DRAIN
14. PISTON SLIDE
15. SHAFT
16. PISTON
17. CAM
18. CONNECTION FOR OPTIONAL HEATER
19. COOLING JACKET DRAIN (2 OF 2)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
19
Figure 1 - Illustration of general operation principle
Figure 11 - Triplex Arrangement

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4.2 SPECIFICATIONS
TABLE 1 - SPECIFICATIONS
UNIT KT-150 KT-300 KT-500 KT-850
FREE AIR
DISPLACEMENT
CFM 150 300 490 780
M³ / H 255 510 840 1325
MOTOR POWER HP 7.5 15 30 40
ROTATION SPEED RPM 1055 870 721 581
OIL CAPACITY
(TOTAL / REFILL)
US GAL. 6 / 5 10 / 8.5 15 / 12.5 28 / 25
LITERS 23 / 19 38 / 32 57 / 47 106 / 95
COOLING WATER
AT 60° F (16° C)
GPM 1 1.5 2.5 3.5
L / MIN 4 6 9 13
COOLING WATER
INLET CONNECTION NPT 1/4” 3/8” 3/8” 3/8”
SUCTION CONNECTION 150 LB. ANSI
FLANGED 3” 4” 6” 8”
DISCHARGE CONNECTION 150 LB. ANSI
FLANGED 2” 3” 4” 5”
HEIGHT WITHOUT
OIL MIST ELIMINATOR
INCHES 43 51 63 71
MM 1092 1295 1600 1803
FLOOR SPACE REQUIRED INCHES 24 × 26 27 × 34 34 × 38 38 × 49
MM 609 × 660 686 × 864 864 × 965 965 × 1245
WEIGHT LBS 800 1,525 2,625 4,175
KG 363 692 1,191 1,894
ULTIMATE PRESSURE MICRONS 10 10 10 10
NOISE LEVEL (TYPICAL AT .1 TORR) DBA 71 72 73 75
WARNING
Do not exceed maximum Rotation Speed (RPM) as stated above.
4.3 MATERIALS OF CONSTRUCTION
HOUSINGS AND CYLINDER: CAST IRON
PISTONS, CAMS, SLIDE PINS: CAST IRON
SHAFT: AISI 1144 STRESSPROOF
SHAFT SEALS: CAST IRON/CARBON/BUNA/VITON®
BALLAST/CHECK VALVE: BRASS/BRONZE

8
5. INSTALLATION
5.1 GENERAL
KT pumps should always be operated with the pump in a vertical and level position. KT pumps should never
be installed in a horizontal or angled position. Pump assembly should be placed on a foundation and should
be supported evenly. Pump assembly should be leveled to within 0.02” (0.5 mm) in any 3.28 ft (1 meter).
SAFETY
DANGER
Internal and external rotating parts of the pump and driving equipment can
produce serious physical injuries. The pump should never be run with the
inlet or discharge piping removed. If it becomes necessary to inspect the
rotating parts of the pump or to change the belt, be absolutely sure that all
power to the motor controls has been shut off, the motor controls are locked
out, and properly tagged before proceeding.
WARNING
Vacuum Pump housing and associated piping or accessories may become
hot enough to cause major skin burns on contact as a result of process
conditions.
WARNING
Use lock out/tag out procedures to disable the electrical energy source
before any service or work is done on the vacuum pumps.
CAUTION
Avoid extended exposure in close proximity to machinery with high intensity
noise levels. Wear adequate ear protection.
CAUTION
Other potential hazards to safety may also be associated with operation
of this equipment. All personnel working in or passing through the area
should be warned by signs and trained to exercise adequate general safety
precautions.
NOTE
Use proper care and good procedures in handling, lifting, installing,
operating, and maintaining the equipment.

9
5.2 LUBRICATION
The KINNEY KT Pump is lubricated by a pressurized oil system. A positive displacement pump generates
oil pressure. KT Vacuum Pumps use Tuthill KV100 oil. KV100 is used for factory testing and the initial
charge is shipped along with the pump. It is necessary to utilize this oil to maximize pump life, achieve
design intents and maintain full warranty. Contact the Factory for review of a desired substitute or inert oils.
The lubricating Gear Pump is mounted on the closed head and is driven directly by the vacuum pump
shaft. Failure of the gear pump may be detected by reduced oil pressure, deteriorating performance, noise,
unusually high temperature and lower temperature of oil line tubing. The tubing should be nearly the same
as the oil temperature or 145 to 165°F (63 to 75°C). If utilizing the high oil temperature switch option it
should be set at 190° F (88° C).
KT pumps are equiped with an oil pressure gauge that should indicate at least 20 PSIG. (1.4 bar) (KT 500
& KT850) and 25 PSIG (1.7 bar) (KT 150 & KT 300).
WARNING
Never attempt to change or add lubrication while the pump is running.
Failure to heed this warning could result in damage to the equipment or
personal injury.
WARNING
Properly dispose of the spent lubricants. Refer to the manufacturer of the
lubricant and any regulations to assure proper and safe disposal.
NOTE
These pumps do not have a bypass valve on the oil pump and pressure
may exceed 150 PSIG (10 bar) on cold start up.
NOTE
If the oil level is too low, bearings and seals will be damaged as a result of
improper lubrication.
5.2.1 HAZARDS ASSOCIATED WITH BREAKDOWN OR IGNITION OF LUBRICATION
DANGER
There is a risk associated with the lubrication media breaking down and
resulting in a hazardous uid or vapor. There may also be a hazard
associated with the ignition of the lubrication media. Refer to the lubrication
manufacture’s applicable instruction for safety precautions.

10
5.2.2 FILLING THE PUMP WITH OIL
For initial oil lling and the rst lling after the pump has been disassembled, the quantity of oil to be placed
in the reservoir is one gallon less than shown in the specications. One gallon is required in the suction port
as outlined in the Suction Manifolding section.
Use oil recommended by Tuthill Vacuum & Blower Systems and see the specications for the quantity of oil
required to ll the pump. Remove the ller plug at the top of the separator housing and add oil until the level
reaches the top of the sight gauge. The level will drop to below mid-center of the gauge once the pump is
operated at blank off and the oil is distributed. Add or drain oil as necessary, to keep the oil level at blank
off 3/8 inch (1 cm) up from the bottom of the glass. The oil level changes with operating pressure, reaching
the lowest level at blank-off.
CAUTION
Do not overll the pump as excess oil will be blown out the discharge during
the high pressure operation of the pump.
5.3 LOCATION
The pump should be mounted on a at and level surface. If it is to be installed outdoors, please ensure
the motor, painting, peripheral equipment, and parts, etc. are suitable for the outdoor operations. There
should be enough space around the pump to allow for safe maintenance work and periodic inspections.
This includes, at a minimum, the ability to access oil ll and drain locations, view the oil level glass and the
oil temperature and pressure gages.
5.3.1 FOUNDATION
The foundation for the pump assembly should be at, level, and have adequate load bearing capacity. The
pump and its base frame, peripheral equipment and piping should be installed after the foundation concrete
has been cured. Systematized pumps and frames should be leveled and secured prior to operation.
5.3.2 INSTALLING THE VIBRAMOUNTS
KT pumps are supplied with vibramounts which enable them to run quietly and vibration free. The pump
can be operated on any oor which will support its weight. The pump must be installed on the vibramounts
and exible connectors tted in suction, discharge, water and electrical connections. It is not necessary to
bolt the pump to the oor.
If the studs are not already installed into the vibramounts, thread the short end into the top of the mount
(smaller diameter) up to the spacer portion of the stud.
The vibramount attachment holes are the four open threaded holes in the anged edges of the cylinder, in
line with the bottom plate/cylinder bolts, just in from each corner of the pump.
WARNING
Do not use the four unthreaded holes, these are used for shipment only.
With the pump lifted off the ground, thread the vibramounts with studs into the vibramount attachment holes
until contact is made between the top of the vibramount and the cylinder bottom plate, and the foot location
is parallel to the pump shaft. See assembly drawing on page 30 for KT850 vibramount locations.
Care must be taken to set the pump down squarely on the mounts when installing the pump in operating
position.

11
5.4 PIPING CONNECTIONS
Manifolding should be no smaller than the pump connections in oder to minimize restrictions to gas ow.
Accurately align the mating anges to the inlet and discharge manifolding to prevent distortion of the pump
housing.
WARNING
Pipe loading on the pump should be negligible as pipe loading can cause
distortion of the pump. Use proper supports and pipe hangers to assure
that there is no loading.
5.4.1 MAIN PIPING
SUCTION MANIFOLDING
Inlet manifolding should be sized and designed with
four objectives in mind:
• To avoid gas ow restrictions.
• To prevent pump uids from entering the process
chamber.
• To protect the pump from the ingestion of
particulate matter.
• To allow proper venting of the pump and suction
manifold.
Under the normal conditions, the diameter of the
manifolding should not be less than the diameter of the
pump connection and the pipe length should be kept
to a minimum.
Oil may splash from inside the pump through the
suction port so the suction line must be designed to
prevent oil from collecting there and draining back to
the system or process. See Figure 2 for recommended
arrangement as a guide for fabricating inlet manifolding.
In all cases the inlet manifolding should include a 90° anged elbow vertically oriented upward to retain
pump oil at low pressures, an isolation valve, and a ex connector, and vent valve.
A exible connection should be installed in the suction manifold to provide freedom for vibramounts. The
vacuum piping must be well aligned with the pump connections so as not to place a strain on the piping.
Provisions for gauge installation and any other drilling in the piping must be made prior to piping installation,
otherwise, drilling particles entering the piping could be entrained into the pump. A vacuum isolation valve
should be installed adjacent to the suction port to be used for leak checking, shutting down the system, or
blanking off the pump.
Before connecting the suction manifolding, distribute 4 quarts of oil over the three slide pins. This will
necessitate reaching through the suction port with a container and pouring oil directly onto the slide pins.
Then rotate the pump by hand a minimum of two revolutions to distribute the oil throughout the pump
interior.
During the initial operation and as long thereafter as necessary, a ne mesh screen should be installed
across the inlet connection to prevent abrasive or solid particles left in the line from being sucked into the
pump. This screen can be removed when particles no longer accumulate. If particles continue to accumulate,
a lter should be installed in the line.
VACUUM
GAUGE
VACUUM
GAUGE
ISOLATION
VALVE
AIR VENT
VALVE
SHUT OFF
VALVE
PUMP
SUCTION
FLANGE
TRAP
DRAIN
TO
SYSTEM
RIGHT
ANGLE
FLEXIBLE
CONNECT
OR
Figure 2 - Detailed Manifold Arrangement

12
PROPER VENTING
The vacuum pump must be properly vented to ensure all oil is removed from the pumping chamber before
the pump is turned off. Also, the suction line must be properly vented to ensure oil does not migrate into the
process chamber.
Recommended vent valve sizes:
KT-150 = .75 inch KT-300 = 1.0 inch
KT-500 = 1.5 inches KT-850 = 2.0 inches
The vent valve must be open for at least 10 seconds before the pump is turned off to remove all oil from
the pumping chamber.
DISCHARGE MANIFOLDING
Discharge manifolding should be sized and
designed to prevent the following:
• Return of oil mist condensate to the
pump
• Oil loss
• Oil mist in the discharged gas.
• Under the normal conditions, the
diameter of the manifolding should not
be less than the diameter of the pump
connection and pipe length should be
kept to a minimum to avoid increased
back pressure.
The installation of an oil mist eliminator
on the discharge is recommended for all
applications, (as shown in Figure 4). Oil
which collects in the eliminator should be
returned to the pump. The oil return kit will
drain oil back into the separator housing
when the pump is operating at low pressure
or when the pump is stopped. If the pump is
to operate continuously, or normal operating
pressure is between 10 torr (13 mbar) and
150 torr (200 mbar), the oil return should
be connected to the gas ballast as shown
in Figure 3. Over 150 torr (200 mbar) the
oil return should be connected to the pump
inlet.
It may be necessary to pipe the pump exhaust
fumes away from the pump area, such as
outdoors. If this is done, the piping must be
arranged to prevent line condensation from
returning to the pump. A exible connector
should be tted in the discharge line to
provide freedom for the vibramounts.
Figure 3 - Oil Return to the Gas Ballast Valve
DISCHARGE
OIL
MIST
ELIMINA
TOR
OIL
RETURN
LINE
GAS
BALLAST
ASSEMBL
Y
OME DISCHARGE
CONNECTION
FIBER OUTER
SHELL (ELEMENT)
SATURATED
ZONE
OIL COLLECTS
AT BOTTOM PRESSURE
GAUGE OR
PRESSURE
RELIEF VALVE
FIBER INNER
SHELL
(ELEMENT)
ALTERNATIVE TO THE
PUMP OIL RESERVOIR
OR GAS BALLAST
VALVE
OIL DRAIN
CONNECTION
OIL DRAIN
CHECK
VALVE
TOP COVER
GASKET
OIL MIST
FROM THE
PUMP (1)
OIL RETURN
CONNECTION
Figure 4 - Oil Mist Eliminator

13
5.4.2 HAZARDS ASSOCIATED WITH HAZARDOUS PROCESS FLUIDS
DANGER
It shall be the responsibility of the installer to ensure that piping is adequate,
sealing between pipe joints is adequate for the process uids and proper
process and pressure protection devices are in place. It is also the
responsibility of the installer to assure that process gasses are not vented
in a manner that would be hazardous. Refer to the manufacturer of the
process media to assure that proper safety precautions are in place.
5.4.3 COOLING WATER
The cylinder cooling water jacket is shipped dry. Fill the water jacket before starting the pump.
If an optional water ow modulating valve (Water Miser) is tted, the cylinder may take 20 minutes or more
to ll. The delay can be avoided by lifting the spring to open the valve. For installation of the valve see
Figure 6.
Failure to ensure that the cooling water jacket is lled before starting the pump will result in localized over-
heating of the pump and cause extensive damage.
For installations requiring starting at ambient temperatures lower than 60°F (16°C), electric heaters should
be installed in the water jacket with an optional temperature switch installed in the separator housing. (see
Figure 5)
WARNING
Do not allow the cooling water to freeze in the pump.
Freezing of the cooling water jacket usually results in extensive damage to the pump cylinder which cannot
be repaired.
Connect a water supply line with “on-off” valve to the water inlet, and an open drain to the water outlet. The
inlet line should have a ow regulating valve. If the water supply is unreliable, it is advisable to install a ow
switch to stop the pump or signal when the ow is interrupted. Normally the cooling water will be off when
the pump is not running.

14
A water pressure relief valve is tted in the water jacket. This
relief valve is set to open at 50 PSIG (3.5 bar).
Standard cooling water rates are for up to 80°F (26°C) supply
temperature and operation within the design of continuous
operating pressure range of .1 to 100 Torr (.13-130 mbar a).
Sustained operation above 100 torr (130 mbar) and/or long
pump downs generally require larger cooling water ow rate
and/or external oil heat exchanger. Larger cooling water rates
increases cooling efciencies reducing heat dissipation to
room temperature and keeps oil cooler (longer oil life and less
oil loss through the oil mist eliminator).
5.5 VACUUM GAUGES
The vacuum gauge(s) to be installed on the pump must be
selected to meet the requirements of the particular pump
application. Two general types of vacuum gauges are used for
the testing of vacuum equipment, total pressure reading, such
as thermistor or thermocouple gauges, and partial pressure
reading McLeod gauges.
The McLeod gauge indicates the partial pressure of permanent gases. It does not indicate the component
of pressure due to vapor such as water vapor. It is not greatly affected by vapor contamination unless the
contamination pressure is quite high. It is most useful in conrming pump performance and for determining
the absence or presence of leaks. A high reading on a thermistor or thermocouple gauge may indicate
that the pump is contaminated or that it leaks, or both. A high reading on a McLeod gauge means that a
leak is present. Total pressure gauge readings will always be slightly higher than McLeod gauge readings
because it includes the partial pressure due to oil vapor at the localized temperatures. The most accurate
total pressure gauges are capacitance manometers and capsule type or avenvolt bellows type that are
independent of the physical properties of the gas or vapor.
6. OPERATION
6.1 GENERAL
CAUTION
Do not operate without guard in place.
Assure that the guard is in place and secure prior to operation.
CAUTION
Do not operate the pump in an enclosed area unless the pump discharge
is ltered or piped to open air. Prolonged inhalation of oil mist or vapors is
a health hazard.
Figure 5 - Water Jacket Heater Installation
Figure 6 - Water Miser Installation
NOTE: Water Inlet and Outlet are
on the opposite side on the KT-150
WATERFLOW
MODULATING
VALVE
(WATER MISER)
TEMPERATURE
SENSING
BULB
OIL
TEMPERATURE
GAUGE
WATER
INLET
(3/8” NPT)
NIPPLE
REDUCING
BUSHING
WATER OUTLET
(DO NOT RESTRICT
OR VALVE)

15
NOTE
Do not block or restrict the ow of gas from the pump discharge. Back
pressure within the pump could cause severe damage.
6.1.1 ELECTRICAL CONNECTIONS
WARNING
Disconnect pump from source electrical power prior to making repairs or
adjustments of any electric component of the unit.
If the pump is not wired when received, wire the motor as per the schematic/label on motor. Also wire any
optional controls prior to start-up. Connect the motor and all applicable electrical accessories to a motor
controller equipped with both overcurrent running protection and short circuit protection.
When wiring is complete turn the pump by hand to ensure that the pump is free to turn and then momentarily
jog the motor to check that the pump rotation direction is clockwise when facing the drive end. If the pump
rotates in the wrong direction reverse any two of the three motor leads. If a ow switch is provided it should
be wired into the motor circuit with a relay so as to stop the motor in the event that the cooling water ow
is interrupted.
Optional custom control panels and electrical accessory components, along with schematic wiring diagrams
and wiring instructions are available separately from Tuthill Vacuum & Blower Systems.
6.2 PRE-START CHECKS
Before starting the pump check the following items:
1. The installation has been made in accordance with the installation section of this manual.
2. The pump has been lled with oil and the cylinder has been lled with water, in accordance with the
installation section of this manual.
3. If the pump has been idle for a month or more – Turn the pump by hand two or more revolutions to
distribute oil internally through the pump.
4. The temperature of the pump oil is 60°F (16°C) or above. Optional pump heaters are available for
installation in the cylinder water jacket.
5. Cooling water is available. Do not start the cooling water ow until the pump has operated a few
minutes.
6. Drive belts are correctly tensioned. See V-Belt Drive Section.
7. Direction of rotation is correct.
WARNING
Correct rotation is clockwise when viewed from the drive end
(Counterclockwise when viewed from the motor fan). Operating the pump
with the incorrect rotation will cause FAILURE.
WARNING
Physical harm may occur if human body parts are in contact or exposed to
the process vacuum. Assure that all connections are protected from human
contact.
CAUTION
Do not touch hot surfaces. Discharge gas based on operating conditions
can be elevated.

16
6.3 PUMP WARM UP
With inlet closed, pump warm up and thermal stabilization is achieved in 20-30 minutes. Warm up can be
expedited by operation in the 20-40 Torr (27-53 mbar a) range after an initial 5 minute operation with the
inlet closed. This can be accomplished with an inlet start purge or, if allowable, a controlled air bleed near
the inlet.
1. Check that the inlet isolation valve is closed.
2. Check that the vent valve is closed. Please note that if the pump was not vented when the pump was
stopped, the following procedure must be used:
a.) Remove power source from the pump.
b.) Remove belt guard from the pump.
c.) Rotate pump, in proper rotation, by hand using drive belts.
d.) Rotate at least 3 full rotations.
e.) Replace belt guard.
3. Start the pump.
4. Open and adjust the cooling water ow as shown in the specications.
5. Maintain oil level 3/8” up from bottom of sight glass when running at “Blank off” conditions (no gas
ballast). The circulating pump (Gear Pump) increases the oil pressure to 20 PSIG (1.4 bar), the check
valve will open and oil will be forced into the pump through the main line.
6. Adjust the Gas Ballast (See the Gas Ballast section). *The small gas ballast valve can be set to quiet
the pump during blank-off conditions and left open if an ultimate vacuum of .05 - .10 Torr (.7 – .13
mbar a) is acceptable.
7. Run the pump at blank off for 5-10 minutes and then with full gas ballast for 10-15 minutes before
opening the suction of the pump to the process by opening the inlet isolation valve.
6.4 PUMP SHUTDOWN
NOTE
Rapid reversal will result in premature failure.
NOTE
KT-series pumps must be properly vented during shut down to insure
normal startup conditions.
1. Close the inlet isolation valve.
2. Open the vent valve while the pump is still operating. If vent valve is not available use the large gas
ballast ball valve. Please note that the vent valve must be opened for at least ten seconds before
removing power from the pump. This will allow all the oil in the pumping chamber to be transferred into
the oil separator housing; so that it will not cause resistance to the internals on the next start up.
3. Close the large gas ballast valve.
4. Stop the pump.
5. Shut off cooling water.
6. Close the vent valve.
6.5 HANDLING LARGE QUANTITIES OF WATER
Use of the gas ballast valve enables Kinney pumps to handle small to moderate amounts of water and other
vapors in the suction gas stream. See the Gas Ballast section.
For applications where the vapor load exceeds that which can be handled by the gas ballast valve, consult
Tuthill Vacuum & Blower Systems about Vapor Handling Systems, which can usually be retrotted to
existing pumps.

17
KT-Series pumps can accumulate .75 - 2.5 gallons (2.8 - 9.5 Liters) of water (depending on the model) in
the reservoir before the water level reaches the oil line pickup where it could circulate through the pump. If
water or other condensate collects in the oil reservoir, the water should be drained before the level reaches
the oil line pickup. To drain water from the pump, crack the oil drain valve and leave it open until any free
water accumulation has drained out. Drain the water as often as necessary. Never shutdown the KT pump
if oil is wet with water since it can separate out and cause damage on startup. Always clean up the oil rst
using gas ballast to remove water vapor before shutting down.
6.6 GAS BALLAST
The gas ballast valve is shown in Figure 1 of this manual. Gas ballast is used while the pump is running,
to prevent internal condensation of oil insoluble vapors such as water, alcohol or acetone and to quiet the
hydraulic noise when running the pump at blank-off conditions.
When gas ballast is used, the ultimate pump pressure increases, more oil mist is created in the pump
discharge, and power consumption increases slightly (within the standard motor rating). Pump noise can be
generally eliminated by using a small ow of gas ballast with only slight increase in ultimate pump pressure.
Continuous use of gas ballast is recommended where the process pressure requirements can be met with
the gas ballast valve open; otherwise, intermittent use of gas ballast between process cycles is suggested.
If use of gas ballast at neither of these times is tolerable; it is advisable to run the pump using full gas
ballast, when process work is not being done such as overnight.
Use the gas ballast valve as follows:
1. CONTINUOUS GAS BALLAST — With the pump operating, open the gas ballast valve until the ultimate
pressure is slightly below that needed for the process. Operate the pump in this manner continuously to
aid in preventing oil contamination.
2. INTERMITTENT GAS BALLAST DURING PROCESSING — With the pump operating, fully open the
gas ballast valve during periods when this will not affect the process (work preparation, recycling, etc.).
This will aid in cleaning the oil.
3. CONTINUOUS GAS BALLAST WHEN NOT PROCESSING — With the pump operating, but isolated
from the process, fully open the gas ballast valve. If convenient, operate the pump overnight in this
manner to clean badly contaminated oil. Gas ballast will remove vapor contamination but will not
remove solids such as varnish. If it is necessary to clean the oil using gas ballast in the short period, the
time needed can be estimated as follows: Open the gas ballast valve fully and operate the pump for a
short period (15 to 20 minutes). Close the gas ballast valve for 1 to 2 minutes and observe the pressure
change. Use the “pressure change versus time” as a rough guide to estimate the total time required to
obtain the desired blank-off pressure.
6.7 STALLING
If the pump stalls at any time, it may be due to loose belts, lack of lubrication caused by failure of the oil
circulating pump, badly contaminated oil, coating build up or foreign matter in the pump or oil line strainer
(KT-500 and KT-850). If the pump cannot be turned over freely by hand after cooling, there is foreign matter
in the pump and the inside of the pump must be cleaned.
Sometimes a process related coating build up can be removed by soaking the pump with the proper solvent
(Turning by hand) – check with Tuthill Vacuum & Blower Systems. Inspecting the inside of the pump is
covered under the Disassembly section.
6.8 PUMP LEAKS
If the pump is suspected of having an air leak, after eliminating oil contamination as the causes of poor
performance, use a plastic sealing compound to seal over suspected areas, such as joints, connections

18
plugs and any penetrations into the vacuum area and check pump blank off performance before making
permanent repairs with Loctite 515. If gasketed connections are suspected, remake the connections. Plastic
sealing compound may be used to make temporary gaskets; these should not be made too thick since the
material may be squeezed into the pump. Check the shaft seal for mechanical defects, such as a cracked
carbon washer or hardened rubber components.
For checking leaks, a fast acting total pressure gauge used with acetone or a sensitive helium leak detector
can be used. A helium leak detector is the most convenient to use if available.
6.8.1 CHECKING PUMP PERFORMANCE
If the processing time or the ultimate pressure becomes poor with no recent changes in the process or in
system conguration, test the pump to determine if the trouble is in the pump or the connected process
equipment. To check the condition of the pump, measure the blank off pressure as directed below using a
McLeod gauge. If possible, also read the blank off pressure with a thermistor or thermocouple gauge. To
read the blank off pressure, close the pump inlet by means of a vacuum valve or blank off plate.
Connect a vacuum gauge to the suction side and position the gauge tube, facing downward in the higher
area of the manifolding so that the tube will not become ooded and blocked by splashing pump oil. If the
pump is disconnected from the process equipment, connect a 90° elbow, extending upward, to the inlet
ange and bolt the blank off plate, with gauge connection to the open elbow ange.
Operate the pump for a minimum of 15 minutes and record the lowest pressure reached. Average blank off
readings are 5 to 25 microns with a McLeod gauge, and 10 to 100 microns with a thermocouple gauge. The
specication pressure is 10 microns, McLeod gauge reading. If the McLeod gauge reading is low and the
thermocouple gauge reading is high, the pump oil is contaminated, see Oil Contamination. A high reading
of both the McLeod and thermocouple gauges indicates that an air leak is present.
6.8.2 CHECKING PROCESS EQUIPMENT
Attach a vacuum gauge (See the Installation - Vacuum Gauges section) to the connection on the system
side of the isolation valve. For this test, the system should be clear of any process work which might give
off vapors and change the reading. Run the pump to obtain the best vacuum possible with the valve open,
then close the valve and observe the pressure rise. If the pressure rise is greater than desired the leaks
should be eliminated. Check the system carefully for loose joints and obvious leaks. Use a leak detector if
available. The trouble can be isolated further by applying the following procedures:
Isolate each segment by valves or blank off plate at convenient locations. Pump down each segment of the
process equipment individually, starting at the segment closest to the vacuum pump.
Check the lowest pressure attainable when each segment is added. If the pressure is close to that obtained
previously, add the next segment. If the pressure is not, leak test the last segment.
When leak-checking process chambers, start at the air and gas inlet valves, doors, sight ports, electrical and
mechanical feedthroughs, gauge tube ttings, and any other gasketed penetrations and O-ring connections.
After a suspected leak has been found, cover it with plastic sealing compound, such as Apiezon Q,or
duxseal and check the equipment performance before sealing the leak permanently. Thus, all permanent
repairs can be made at the same time.
If a leak detector is not available, use the following methods to locate leaks:
1. Cover suspected leaks with a low vapor pressure sealing compound such as Apiezon-Q or duxseal.
Do this while pumping on the equipment and monitoring the pressure. A sudden decrease in pressure
indicates that a leak has been covered. Repair leaks permanently as necessary.
2. If the leak is large, causing pressures less than 1 torr (1.3 mbar), pressurize the process equipment
with 1 PSIG (70 mbar), of clean compressed air and paint a soap solution on suspected leak areas and
bubbles will indicate leaks.
3. If the leak is small causing pressures less than 1 torr (1.3 mbar), use a fast acting medium such as

19
acetone, alcohol, freon or helium. Position the vacuum gauge head downstream from the suspected
leak area, between the leak and pump. When the pressure has been reduced so that the gauge may be
used , apply probing medium to suspected leak areas using a squirt gun or brush . If the probing uid
is directed at the leak or an area close to it, a sudden change in pressure will occur. Cover suspected
leaks with plastic sealing compound and continue leak checking until desired pressure is obtained.
4. If leak checking fails, disassemble and remake all demountable joints and connections using new
gaskets or vacuum sealing compound such as Loctite 515. Temporary gaskets maybe fabricated from
plastic sealing compound but these should not be made too thick since the material may be squeezed
into the equipment.
7. MAINTENANCE
7.1 GENERAL
During normal operation, the temperature in the pump will increase in homogeneous manner as a result of
compression work done on the process gas or vapor. It is abnormal if the temperature rise is localized in the
pump and/or the external paint becomes scorched. Localized hot spots are typically due to an inadequate
cooling liquid supply or cooling liquid cut-off, interference of the piston with cams, slide pins, or cylinder, or
because the pump has ingested foreign material, such as solid particulates, metal chips, process material
build up etc. If a localized hot spot is observed, the pump must be shut down immediately for inspection.
Most of pump abnormalities can be noted by routine checks of temperatures, vibration and noise etc. Daily
inspection of the pump is highly recommended as a preventative maintenance. Whenever the pump is
stopped, completely drain the cooling liquid if the pump is located in a cold region or in the winter to prevent
freezing of the cooling liquid.
DANGER
The pump and parts may contain hazardous media as determined by the
process. Assure that pump and parts are evacuated of hazardous media
prior to servicing.
CAUTION
The electrical service must be isolated and de-energized prior to
maintenance. Apply appropriate procedures to assure electrical supply is
de-energized and cannot be inadvertently energized during maintenance.
Assure piping and product are isolated prior to maintenance of pump.
Apply appropriate procedures to assure piping and product is isolated and
that inadvertent opening of valves cannot occur during maintenance.
7.2 PERIODIC MAINTENANCE
There is no xed interval for changing pump oil, since applications vary widely. This can be determined
only by experience and/or by deterioration of pump performance. As a minimum, the pump oil should be
changed after each six month logged period of operation.
At high pressures, or with a gas ballast ow the oil level should be higher than it is when operating at low
pressures near blank off. If there are no changes in the oil level, check for obstructed oil passages. Check
the condition of the oil periodically by draining a small quantity of oil into a clean container and visually
inspecting it for solid or liquid contaminants. Clean strainer after oil pump (KT-500 and KT-850).
7.2.1 CHANGING THE OIL
Run the pump until the oil reaches normal operating temperature 145 to 165°F, (63 to 75°C) and below 100
torr (130 mbar). Stop the pump, place a container under the oil drain valve and open the valve until the oil
is removed from the pump, then close the valve.

20
If the oil is being drained due to oil contamination, it is advisable to drain the oil from the discharge valve
well. The well is between the pump cylinder and separator housing, the oil trapped there can be drained by
removing the pipe plug(s) from the cylinder located above the heads.
When the oil has drained from the pump, close all drains and ll the pump with the quantity and type of oil
shown in the specications. The oil level will show above the center of the sight gauge until the pump is
started and the oil is distributed through the pump.
7.2.2 OIL CONTAMINATION
When the pump has operated satisfactorily for some time and then gradually the vacuum performance
becomes poor, clean the oil by applying gas ballast, or change the oil as directed in the Changing The Oil
section of this manual. A change in the color of the oil does not necessarily mean that is not satisfactory for
use. On the other hand, vapors may contaminate the oil and not show any color change.
The following factors may cause the pump oil to deteriorate:
• Water and solvents will lower viscosity
• Solid accumulation will increase viscosity and “feel gritty”
• Polymerization and chemical attack on oil will increase viscosity and odor
As a “Rule of Thumb” the oil should be changed if:
• The oil “feels gritty”
• Viscosity changes more than 100 SSU @ 100°F (38°C)
• Oil color becomes opaque
• Smells burnt or acrid smell occurs
• Total Acid Number increases to 0.3
In a new application, it is recommended that the oil be changed at intervals of 500 hours operation, and that
depending on the condition of the oil after that period of operation, according to the guideline above, the oil
change interval be reduced or increased.
If oil contamination is suspected, change the oil and operate the pump for 15 to 30 minutes. Repeat this
procedure as required to ush out all contaminants from the pump or operate the pump with gas ballast as
explained under the section. See Gas Ballast and Water Handling sections.
Oil ltration systems are available for ltering solids, water, and acids continuously or periodically.
7.3 REPLACEMENT PARTS
Replacement parts for the KT-150 C Series and KT-300, KT-500 and KT-850 D Series pumps used with
standard hydrocarbon vacuum pump oil are shown on pages 30 & 32. Two levels of maintenance kits are
available for the KT line of pumps. Contact the factory with Serial Number information for kit part numbers
and delivery can be provided at that time.
Various parts particularly internal components for earlier versions of KT-series pumps are different and
cannot be interchanged. Many pumps are ordered and equipped with special modications and accessories,
or adaptations for special uids. Therefore when ordering spare parts the pump model and nameplate serial
number must always be provided to insure verication and shipment of the correct parts.