Tuthill KMBD-240C User manual

Manual 1857
-
1
Models:
KMBD-240C
KMBD-400C
KMBD-540C
KMBD-720C
KMBD-850C
KMBD-1200C
KMBD-1600C
KMBD-2000C
KMBD
-
2700C
KINNEY
VACUUM
BOOSTERS
Instruction Manual
Revision 12/99
ISO 9001
CERTIFIED
QUALITY SYSTEM

TABLE OF CONTENTS
INTRODUCTION.......................................................................................... 1
DESCRIPTION.............................................................................................. 1
Flow Direction by Rotation..................................................................................2
INSTALLATION............................................................................................ 3
General...................................................................................................................3
Safety.....................................................................................................................3
Lubrication ...........................................................................................................4
Water Liquid Cooling Instructions ....................................................................5
Piping Connections...............................................................................................5
Water Cooled End Plate Option.........................................................................6
C-flanged Coupling Installation..........................................................................7
Electrical Connections.........................................................................................8
OPERATION.................................................................................................. 8
Starting .................................................................................................................8
Operating..............................................................................................................8
Stopping ...............................................................................................................8
MAINTENANCE........................................................................................... 9
General..................................................................................................................9
Spare Parts............................................................................................................9
Repair Service.....................................................................................................10
Long Term Storage............................................................................................10
DISASSEMBLY–240C & 400C............................................................11-12
ASSEMBLY –240C & 400C.................................................................13-17
DISASSEMBLY –540C, 720C, 850C, 1600C, 2000C, 2700C.............18-19
ASSEMBLY –540C, 720C, 850C, 1600C, 2000C, 2700C ...................19-23
TROUBLESHOOTING .............................................................................. 23
PARTS LIST 240C & 400C......................................................................... 24
PARTS LIST 540C & 720C......................................................................... 25
PARTS LIST 850C, 1200C, 1600C, 2000C, 2700C................................... 26
METRIC CONVERSION CHART............................................................ 27
DRAWINGS 240C & 400C.....................................................................28-29
DRAWINGS 540C & 720C.....................................................................30-31
DRAWINGS 850C, 1200C, 1600C, 2000C, 2700C, 2700C..................32-33

1
INTRODUCTION This manual covers the Installation, Operating, and Maintenance of
the Mechanical Booster Pumps listed in Table 1.
KMBD Models (1) (2)
240C, 400C,
540C, 720C,
850C, 1200C,
1600C, 2000C,
2700C
Mechanical Seals Slinger Seal
Table 1
(1) Interconnecting cooling water between drive shaft bearing housing and the
two oil reservoirs. Mechanical seals are used throughout.
(2) Water cooled only at drive shaft bearing housing. Rotor seals are slinger
type and a mechanical seal on the drive shaft.
DESCRIPTION Kinney Vacuum Boosters are lobe type, positive displacement units,
designed with extra heavy shafts and bearings to permit high power
input. They incorporate a unique rotor profile in which all gas joints
or mating surfaces are sealed vacuum tight.
Unit construction consists of two figure eight shaped rotors enclosed
in a precision machined housing supported at each end by precision
bearings. The power drive turns the drive rotor directly and rotates
the driven rotor by means of specially forged, heat treated, crowned
and ground precision helical gears.
Efficient and effective vacuum pumping is accomplished by
trapping a volume of gas at the booster inlet and between each rotor
and the booster housing. This volume of gas is quickly and cleanly
evacuated by the fast revolving rotors which carry the air to the
exhaust side of the booster where the air is then discharged to the
backing pump.

2
Flow Direction
by Rotation Refer to the illustration below before installing inlet and discharge
piping.
KMBD
Model Approximate Oil Capacity Port Size Max.
Vertical Horizontal inch (mm) RPM Vertical Horizontal
400
400BP 1 Quart (0.95 Litre) 0.5 Quart (0.47 Litre) 4 (100) 2 (51)
3600
195 (90)
400 (180) 180 (90) N/A
540
720
720BP
1.5 Quarts
(1.42 Litres) 1 Quart (0.95 Litre) 4 (100) 4 (100)
2.5 (63.5)
260 (120)
300 (135)
560 (255)
240 (110)
280 (130)
N/A
N/A
850
1200
1600
2000
2700
4 Quarts
(3.79 Litres)
2.5 Quarts
(2.37 Litres)
**
6 (150)
10 (250)
430 (195)
510 (252)
580 (265)
685 (310)
790 (360)
450 ( 205)
500 (248)
540 (245)
645 (295)
750 (340)
Approximate Weight lbs. (kg)
Table 2 Specifications

3
INSTALLATION
General Carefully check to ensure that no transit damage has been sustained.
If damage has occurred from shipment a claim must be filed with
the carrier immediately; preserve the shipping container for
inspection by the carrier. Do not return the booster to the factory
without first obtaining shipping instructions from Tuthill Vacuum
Systems.
Remove protective covers and plugs only as connections are made.
Mount the booster on a flat, level surface of sufficient rigidity.
Shim under the legs where necessary so as to have each leg of the
booster support a proportional share of the booster weight. This is
necessary to prevent eventual twisting of the booster.
Safety Booster housing and associated piping or accessories may become
hot enough to cause major skin burns on contact.
Internal and external rotating parts of the booster and driving
equipment can produce serious physical injuries. The booster
should never be run with the inlet or discharge piping removed. If it
becomes necessary to inspect the rotating parts of the booster or to
change V-belts, 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.
Avoid extended exposure in close proximity to machinery with high
intensity noise levels. Wear adequate ear protection.
Use proper care and good procedures in handling, lifting, installing,
operating, and maintaining the equipment.
Other potential hazards to safety may also be associated with
operation of the equipment. All personnel working in or passing
through the area should be warned by signs and trained to exercise
adequate general safety precautions.
CAUTION
Disconnect and lockout power source before any work is started.

4
Lubrication Before starting the booster fill reservoir as instructed below:
1. Remove fill plugs from gear end and free end plates.
2. Pour oil through fill hole until oil appears in sight glass. Slowly
bring oil up to center of glass. See Figure 1.
3. Reseal plugs and reinstall in end plates.
Oil levels should be checked frequently. Booster must be shut
down to properly check oil level.
Note: Oil may not be added while booster is operating. Oil
reservoirs are under vacuum.
Time lapse between oil changes will vary depending on operating
conditions. Higher blower operating temperatures are directly
related to higher oil temperatures. Boosters utilizing the water
cooling option can extend the interval between oil changes by a
considerable amount. Consult the factory if temperature questions
arise.
Every Kinney booster is factory tested, oil drained and shipped dry
to its installation point. Oil reservoirs must be filled to proper level
before operation.
Boosters with mechanical seals are splashed lubricated. One or both
gears dip into an oil reservoir on the drive end to lubricate bearings
while an oil slinger provides the same lubrication on the opposite
end.
Figure 1 Lubrication
KMBD 240C & 400C models are similar
except the sight gauges are inverted.
Some horizontal flow boosters may
have bulls-eye sight gauges. Maintain
oil level in center of glass.

5
Water Liquid
Cooling
Instructions
Entrance into the water jacket cavity is through any of the (5) 1”
NPT cooling connection holes in each end plate. For best results,
the cooling liquid should be introduced at the bottom of the end
plates and exits at the top in a diagonal direction as shown below
COOLING WATER SPECIFICATIONS
Flow rate: Depending on operating conditions, 1/2 to 1 gallon per
minute will be required for both end plates.
Maximum Pressure: 75 PSIG
Kinney KV-100 oil is recommended for use on boosters with typical
vacuum applications. Consult Tuthill Vacuum Systems on oils for
use where hazardous or chemically active materials may be present.
Add vacuum oil to the booster in the quality shown in
Specifications on page 2. The oil level must be maintained within
the notched area of the sight glass. See figure 2.
WARNING: Never attempt to change or add oil while booster is
running. Failure to heed this warning could result in damage to the
equipment or personal injury.
Piping Connections Manifolding should be no smaller than the pump connections in
order to minimize restrictions to gas flow. Accurately align the
mating flanges to the inlet and discharge manifolding to prevent
distortion of the booster housing. Temporarily fit a fine wire mesh
filter at the suction port if solid particles are likely to be entrained
into the air stream and remove the filter when particles no longer
appear. This is especially desirable on new installations and when
manifolds have been welded. The manifolding to and from the
booster should be fitted with flexible connections to isolate
vibrations, absorb expansion and contraction due to thermal
change, and to absorb misalignment differences. If the booster is to
be water cooled, connect a clean supply to the ¼” NPT connection
on the seal adapter housing adjacent to the drive shaft. The drain
line will be connected on the bottom of the non-drive end reservoir,
see Figure 3 for connection locations.

6
Figure 3 Cooling Water Piping Harness
The partly water-cooled slinger seal version has cooling water to the
seal adapter housing only. The cooling coils and interconnecting
water line are omitted and the interconnecting line leading from the
seal adapter housing is led to the drain.
The air-cooled configuration requires no cooling water. However,
cooling water can be circulated through the seal adapter housing on
most models without modification to the booster. Cooling the
bearing housing will prolong the life of the mechanical seal therein.
An on-off valve should be provided on the incoming line and a
regulating valve located in the drain line. The drain line should
terminate at an open drain to enable the operator to better regulate the
water flow.
Water Cooled End
Plate Option Units having water cooled end plates can be identified by the
connecting hose which runs from the top of the drive end plate to the
bottom of the rear end plate. See Figure 4.
Units that will operate with continuous discharge gas temperatures of
250° F (121° C) or more must be connected to a water (liquid) supply
in order to maintain reasonable oil temperatures. Generally a water
flow of ½ to 1 GPM (1.9 -3.8 L/min) is sufficient to maintain oil
temperatures below 150° F (65° C).
WARNING: If unit is to be located outside or in a building where

7
ambient temperatures can fall below freezing then care must be taken
to ensure the water or liquid used for cooling does not freeze and
damage the blower end plates. End plates must be drained of liquid
during downtime unless a recirculating unit using a glycol mixture
has been installed.
NOTE: Units are never shipped from the manufacturer with liquid in
the end plates.
COOLING WATER SPECIFICATIONS
Flow rate: Less than 2 GPM (7.6 L/min) total for both end plates.
Maximum Pressure: 100 PSIG (6.895 bar G)
1/4” Inlet
(Far Side)
3/4” Outlet
Round Oil
Sight Glass
Woods Coupling
1. Inspect all coupling components and remove any protective
coatings or lubricants from bores, mating surfaces and fasteners.
Remove any existing burrs, etc. from the shafts.
2. Slide one coupling flange onto each shaft, using snug-fitting keys
where required.
3. Position the flanges on the shafts. It is usually best to have an
equal length of shaft extending in to each flange. Move one
flange to its final position. (Usually the motor shaft.) Torque
fasteners to proper value. Slide the other flange far enough away
to install the sleeve. With the two piece sleeve, do not move the
wire ring to its final position, allow it to hang loosely in the
groove adjacent to the teeth.
4. The coupling employs a two-piece sleeve with a wire ring. Force
the ring into its groove in the center of the sleeve. It may be
necessary to pry the ring into position with a blunt screw driver.
5. CAUTION: Coupling sleeves may be thrown from the coupling
assembly with substantial force when the coupling is subjected to
a severe shock load or abuse.
C-Flanged
Coupling
Installation
Figure 4 Mechanical Seals-Water Cooled End Plates

8
Electrical
Connections Wire the motor and other electricals such as solenoid valves and
temperature switch to the proper voltage and amperage as indicated
on the nameplate of each component being wired. Turn the booster
by hand after wiring is completed to determine that there are no
obstructions and if the booster turns freely; then momentarily start
the booster to check the direction of rotation. The illustration on
page 2 shows direction of air flow in relation to rotor rotation. The
air flow direction can be reversed by reversing the appropriate
motor leads.
OPERATION
Starting the Pump Check the oil for proper level at both ends of the booster. Add or
drain oil as necessary to bring the oil to the correct level. See Figure
1. Too much oil particularly on the gear end can result in excessive
heat generation. Too little oil will possibly result in failure of the
timing gears, bearings, and mechanical seals.
Start the backing pump. When pressure is reduced sufficiently, start
booster pump. A pressure switch can be installed to start the
booster at a predetermined pressure. If the booster is water cooled,
turn on the cooling water when the booster is started. Adjust the
water flow so that the discharge water temperature is no more than
lukewarm (70°to 80°F).
Operating The upper temperature limits for booster pump operation are
between 350° and 375° F measured in the exhaust gas stream with a
thermocouple. When this temperature limit switch is installed, as
the temperature exceeds the predetermined temperature, the booster
motor will stop and cannot be restarted until the temperature drops
below the trip setting of the temperature switch.
NOTE: These upper limits are not for continuous operation.
Consult Kinney for detailed information or assistance.
CAUTION: Use of a thermowell insulates the thermocouple.
Invalid and delayed reading will result. This can result in
ineffective protection devices.
Stopping the
Booster CAUTION: Venting the booster to pressures above cut-in while
running can damage the booster.
Stop the booster by turning off the motor. Isolate the booster
from the vacuum system and vent the booster to atmosphere.
Turn off the cooling water if water cooled. Stop the backing
pump. Refer to component instruction manual.

9
MAINTENANCE
General Scheduled maintenance consists of changing lubricating oil every
250 to 1500 hours of operation. Change the oil more frequently if
pumping corrosive vapors or where excessive operating
temperatures are encountered. Boosters with mechanical seals on
the rotors can generally run the full 1500 hours before an oil
change is required.
Proper oil drain schedules require oil to be changed before the
contaminant load becomes so great that the oil’s lubricating
function is impaired or heavy disposition of suspended
contaminants occur. To check the condition of the oil, drain a
sample into a clean container and check for the presence of water
or solids. Slight discoloration of the oil should not necessitate an
oil change.
NOTE: When changing oil be sure to reseal the drain and fill
plugs. This is especially important on slinger seal series which
have no mechanical seals on the rotors. Air leaks past these plugs
can cause rapid loss of oil from end covers resulting in booster
failure. Oil levels should be checked every 24 hours of operation.
Spare Parts Refer to the parts list and assembly drawing for your particular
model. Repair kits are available for all models. These kits contain
all the seals, bearings, o-rings, locks and special retaining screws
necessary for an overhaul. Always have complete booster model
number and serial number when ordering.
In developing a stock of spare parts, consider the following:
1) The degree of importance in maintaining the booster in a “ready”
condition.
2) The tie lag in parts procurement.
3) Cost.
4) Shelf life (seals and o-rings).
Contact Tuthill Vacuum Systems Sales Department for any
assistance in selecting spare parts.

10
Repair Service With proper care Kinney Vacuum Boosters will give years of
reliable service. The parts are machined to very close tolerances
and require special tools by mechanics who are skilled at this work.
When ordering parts, give all booster nameplate information, plus
the item numbers and names as taken from the appropriate assembly
drawing in this book. Numbers shown in brackets ( ) in the
following repair procedures correspond to item numbers in the
drawings.
Should major repair become necessary, it is strongly recommended
that the booster be returned to the factory for repair or to one of the
authorized service facilities that specialize in vacuum booster repair.
Contact the factory for the location nearest you. Units which are
still under warranty must be returned to Tuthill Vacuum
Systems (TVS) for service.
NOTE: Before returning any unit, you must call TVS Service
Department [phone], for authorization and proper return
procedure.
If your in-house mechanics have been properly trained in booster
repair, special assembly tools are available through TVS Service
Department.
Long Term
Storage 1. Spray the interior (lobes, housing and end plates) with rust
preventative.
2. Fill both end bells completely full of oil.
3. Firmly attach a very prominent tag stating that the end bells are
full of oil and must be drained and refilled to proper levels prior
to startup.
4. Apply a rust preventative grease to the drive shaft.
5. Attach a desiccant bag to either of the covers to prevent
condensation from occurring inside the booster. Make sure any
desiccant bag (or bags) is so attached to the covers that they will
be removed before startup of the booster.
6. Store the booster in an air conditioned and heated building if
possible. At least insure as dry conditions as possible.
7. If possible, rotate the drive shaft by hand at least monthly in order
to prevent the seals from setting in one position.

11
DISASSEMBLY
KMBD-240C &
KMBD-400C
1) Disconnect cooling water lines (274 & 181). Do not disturb
cover bushings (120) or it will be necessary to retest cooling coils
for leakage as described in the assembly procedure. Covers
should be re-tested if water is detected in drain oil, (mechanical
seal boosters only).
2) Drain oil from both ends of booster and remove inlet and outlet
port fittings (38 or 48).
3) Remove bolts (93), use jack screw holes to remove seal housing.
Remove cover using jack screws. Seal mating ring will come off
with cover.
4) Remove cap screws (26A & 26B and both end covers (6 & 7).
Two jack screw holes are provided on each other.
5) Remove lockwire (49), socket head screws (66), and drive shaft
(45).
6) Remove flat head allen screws (29) from end of each rotor shaft.
Remove washer (25), spacers (57), and oil slinger (21).
NOTE: The flat head screws have nylok in their threads and may
be difficult to remove. Strike the head a couple of blows with a
flat face hammer for easy removal.
7) Mark housing, end plates, rotors and gears before proceeding
with disassembly. There are two methods which can be used to
disassemble the rest of the unit. Method “A” requires an arbor
press while Method “B” requires the use of bar or yoke pullers.
8) Align timing marks on gears (Figure 6A). Rotate drive gear
clockwise approximately three teeth and mark a matching
reference line on each gear as shown in Figure 6B. This gear
position is necessary so rotors will clear and not jam. Do not
allow the gears to move from the matched reference line while
pulling. Use a light rocking motion to insure that the lobes have
not jammed. Remove driven gear first then drive gear.
WARNING: Failure to properly pull this gear could result in
damage to rotor keyway or a bent rotor shaft. Never use excessive
force.
9) Remove button head allen screws (30) and bearing retainer rings
(14) from both end plates.
10) Attach a pair of bar pullers to the bearing bores of the free end
plate. Use 10-32 x 4” long screws. Alternately push both rotors
from the end plate. Separate end plate from housing.

12
11) Turn the unit around and attach a single bar puller to either bore
and push rotor from end plate making sure the rotor is vertical in
the housing (for support) while removing. Repeat for opposite
rotor. Note the location of timing shims (16), oil slinger (20),
and spacers (17 & 18).
12) Tap end plate from housing.
13) Mechanical Seal Boosters –Tap out bearings from both end
plates. Note location of spacers under bearings and retain for
reassembly. To remove seals (54) use a cape chisel or similar
tool, being careful not to nick or cut the bearing or seal bores.
Remove the labyrinth seal (51) in the same manner. The seals
will be damaged by removal and must be replaced.
Slinger Seal Boosters –Carefully tap out seal slinger (238),
spacer (123), and bearings. The oil slinger stator (79) should not
be removed unless it is damaged or the end plate is to be
replaced.
NOTE: On some older units the oil seal slinger is made up of
two separate parts, items 238 & 129. The newer design
combines these two parts and is identified as item 238.
14)Clean all parts with a good grade of clean solvent and replace any
worn or damaged parts with factory approved parts. New
bearings, seals, and o-rings should be installed at each assembly.

13
Drive Gear Driven Gear
Keyways in line and timing marks matched
Figure 6A
Drive Gear Driven Gear
Timing marks advanced 3 teeth
(Reference marks aligned)
Figure 6B
NOTE: Position of
timing marks is for
removing or installing
driven gear. To remove
the drive gear, advance
three teeth in the
opposite direction.
ASSEMBLY OF
KMBD-240C &
KMBD-400C
The assembly procedure is generally the same for all series, but where
there are differences notations will be made.
All vacuum joints, end covers, seal casings and plugs should be sealed
with an RTV Silicone Sealer, Kinseal or equal, unless o-rings have
been provided.
Dowel pins are used to locate end plates, housing and drive end cover
in the proper location relative to each other. Be sure they are in place.
It is recommended that the gear end rotor shaft bearings be purchased
from Tuthill Vacuum Systems, as they are specially ground to locate
the rotors with correct end clearance relative to the gear end plate. Do
not use standard bearings which have not been flush ground
within .001 tolerance. Use factory approved parts only.
General

14
It is suggested that long feeler gauges (12”) be used to check the
interlobe timing. Preferably (2) .006, (1) .005, (1) .004, and (1) .003
These gauges will provide all the combinations from .003 to .021,
and also .024, which is the total.
Preparation Of End
Plates For Assembly 1) Remove all nicks, scratches, etc. from all sealing surfaces. Clean
all parts thoroughly.
2) Mechanical Seal Boosters –Press in new labyrinth seals (51)
into bores of both end plates (4) making sure the scalloped areas
of seal case are aligned with openings in vent area of seal bore.
Coat O.D. of mechanical seal with sealer and press into seal bore,
coming to rest on top of labyrinth seal. Make sure seals are fully
seated without deforming case. Keep sealer from carbon surface.
Carefully wipe carbon with soft tissue and cleaning agent
(acetone) before continuing assembly.
Slinger Seal Boosters –Press in new oil slinger stators (79) if
required.
3) Stand rotors (1) on arbor press table with gear end shafts up. See
Figure 7. Two keyways should point in the same direction, to the
right.
Figure 7
4) Carefully install gear end plate over rotor shafts.
NOTE: The drive rotor should always be on the left side. Make
sure the end plate feet are facing in the proper direction so the
assembled unit will have the same drive shaft location as before.
5) Mechanical Seal Boosters –Some earlier models used an o-ring
(314) under the mating portion of the mechanical seal. This has
been discontinued and o-rings should not be used with newly
purchased seals. Check lapped surface of seal mating ring to be
sure it is perfectly clean. Use soft tissue and cleaning agent if
necessary. Place a few drops of lubricating oil on its surface and
install on shaft with lapped surface coming to rest on top of
carbon. Gently press with fingers to insure compression is taking
place and ring is not hung up for any reason.
Slinger Seal Boosters –Slide slinger (238) over shaft. Also
install spacer (129) if two piece.
Gear End Assembly

15
6) Lubricate shafts and press the double row ball bearings (9) onto
rotor shafts and into end plate bores.
CAUTION: These bearings have been flush ground at the
factory. The inner race will have a black dot etched on the
surface. This dot must be up and visible when bearings are
installed. Secure with bearing retainers (14), and socket head
screws (30).
7) Check clearance between the face of the end plate and rotor
lobes. See exploded view for correct gear end clearances. If
clearances are not within specifications, recheck parts to find
cause of improper clearances before proceeding.
8) Install spacer (17) (.260 thickness) on one shaft and spacer (18)
(.200 thickness) and oil slinger (20) on the other shaft.
NOTE: Oil slinger and its spacer should always be mounted on
lower rotor for horizontal flow units. It can be mounted on either
shaft for vertical flow units.
Install timing shim in same location as found in disassembly.
This does not necessarily insure the unit will be in proper time.
Adjustments can be made later in the assembly process.
9) Insert gear keys (24) in their proper location and flush with top of
shaft. Use the two keyways facing to the right. Tight fit
required. Coat shafts and keys with lubricant. Install drive gear
(right hand helix) on drive rotor (left side). To install driven
gear, align reference marks as shown in Figure 6B. Install driven
gear carefully to avoid mashing any teeth when engaging
opposite gear. Secure with spacers (57), washers (25), and flat
head allen screws (29).
NOTE: All timing gears must be used in sets, as they are
matched and serially numbered.
10) Remove assembly from press and stand on work table with
gears facing downward. Place blocks under end plate to prevent
assembly from falling over. Drive gear should remain on left
side.
11) Place small bead of sealer around the periphery of the end plate,
encircling each bolt hole. Install rotor housing (3) and secure
with 4 screws evenly spaced.
12) Check clearance between end of lobes and housing using a flat
bar and feeler gauges or a depth micrometer. Refer to exploded
view for free end clearances.
13) Place a small bead of sealer around the periphery of the housing,
encircling each bolt hole. Install free end plate and secure with 4
screws.
Installation of
Timing Gears
Housing and Free
End Assembly

16
14) Mechanical Seal Boosters–Install mating rings same as gear
end, No. 5.
Slinger Seal Boosters – Install seal slinger same as gear end.
Install bearing spacers (123) on each shaft.
15) Lubricate shafts and install roller bearings (10).
CAUTION: Inner race of bearing has a flange on one side only.
This flange must face outward. See Figure 8.
16) Install oil retainer rings (14) with button head screws (30). Only
two required for each ring.
17) Install spacer (67) on each shaft. Install oil slinger (21) on
lower rotor, (either shaft on vertical flow units) spacer (57) on
opposite shaft, washers (25), and screws (29). Lay assembly
down with drive on left for timing.
18) Using feeler gauges take interlobe readings and record on each
side of housing as indicated in Figure 9. By removing or adding
shim behind the helical gear, it rotates as it is moved in or out
and the driven rotor turns with it, thus changing the clearance
between rotor lobes. Changing the shim thickness .006 will
change the rotor lobe clearance .003 or one half the amount.
EXAMPLE: Referring the Figure 6, check the clearance at AA
(right hand reading) and BB (left hand reading). If AA reading
is .009 and BB reading .003 by removing .006 shims, the
readings will change one half the amount removed or .003. AA
should then read .006 and BB should read .006. The final
reading should be within .002 of each other.
To determine the amount of shim to add ore remove, subtract
the small figure from the larger. If the right side reading is
higher than the left side, remove shim. If the right side reading
is lower, add shim.
19) Install drive shaft (45) and secure with allen screws (66). Check
drive shaft runout behind keyway. Do not exceed .002 T.I.R.
(Total Indicator Reading). Install lockwire (49).
20) Remove temporary cap screws from gear end plate and apply a
bead of sealer around end plate (not cover), encircling all holes,
and install gear cover (6) and secure with cap screws (26A).
NOTE: If cooling coil or fittings were disturbed or water was
detected in drain oil, they should be retested with air pressure to
check for leaks and resealed. (Mechanical Seal Boosters only.)
21) Install cover (6).
22) Install new mechanical seal (76) into seal housing (91), and
press in lip seal (13).
23) Install mating ring (76) onto drive shaft and install assembled
seal housing.
24) Be sure to lubricate seals before final assembly.
Adjusting Rotor
Interlobe Clearance
Drive Shaft Seal
Assembly

17
Complete Booster
Assembly 25) Install free end cover (7) following the same procedure used to
install the gear cover. Secure with cap screws (26B).
26) Apply sealer and install both port fittings (38 or 48).
27) Install all necessary cooling water lines.
28) Prior to putting booster into operation, follow Installation and
Operation instructions. Observe the oil level frequently, during
the initial hours of operation. A badly installed or damaged oil
seal will result in oil loss.
Figure9
Figure 8

18
DISASSEMBLY
KMBD-540
KMBD-720
KMBD-850
KMBD-1600
KMBD-2000
KMBD-2700
1) Disconnect cooling water lines (274 & 181). Do not disturb the
large hex head screw (97). If it is removed, loosened, or water is
detected in drain oil, the coil assembly must be retested as
described in the assembly procedure.
2) Drain oil from both ends of booster and remove port fittings (38
or 48).
3) Remove motor and drive coupling.
4) Remove bolts (93) and take off seal housing (91) using jack
screws.
5) Remove cover (6), mating ring (76) will come off with cover.
6) Remove drive shaft screws (66) and locks (65). Tap shaft lightly
to remove.
7) Remove gear lock nuts and washers (35 & 36). Models KMBD-
850C, 1200C, 1600C, 2000C, and 2700C (horizontal flow series,
top drive only). Remove cap screws (396), washers (136 & 80),
and oil slinger (20) if furnished. These items are not shown on
exploded view but are listed on parts list.
8) Position the timing gears for pulling by first matching the timing
marks on the gears. See Figure 10A. Turn the drive gear
clockwise five teeth and mark a matching reference line on each
gear as shown in Figure 10B. The rotor lobes are now in their
most open position. Using a gear puller, the driven gear (left
hand helix) may now be removed without jamming the rotors.
This gear is in two parts –the gear rim and hub. It is not
necessary to disassemble. Do not allow the gears to move from
matched reference line while pulling. Use a light rocking motion
while pulling the gear to insure that the lobes have not jammed.
WARNING: Failure to properly pull this gear could result in
damage to rotor keyway or a bent rotor shaft. Never use
excessive force.
9) Remove drive gear. It is not necessary to remove keys from rotor
shafts.
Figure 10A Figure 10B