Tuthill KINNEY KT150 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

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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

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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.

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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
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Do not touch hot
surfaces.
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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.

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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

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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.

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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.

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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.