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Table of Contents

Manual 1807 Rev B p/n 001807 0000

Pre-Start Checks ................................................................................. 10

Operation .....................................................................................11

Starting the Pump ............................................................................... 12

Stopping the Pump ............................................................................. 12

Gas Ballast .......................................................................................... 12

Special Refrigeration Service Pumps  ................................................ 13

Maintenance ............................................................................... 14

Periodic Maintenance ......................................................................... 14

Changing the Oil ................................................................................. 14

Flooding .............................................................................................. 15

Oil Mist Eliminator ............................................................................... 15

Stalling ................................................................................................ 17

Troubleshooting ......................................................................... 18

Checking Pump Performance ............................................................. 19

Pump Leaks ........................................................................................ 20

Checking Process Equipment ............................................................ 20

Process Equipment Leaks .................................................................. 20

Leak Checking Techniques ................................................................. 21

Oil Contamination ................................................................................ 21

Discharge Valve .................................................................................. 21

Shaft Seal ............................................................................................ 22

Disassembly ............................................................................... 24
Reassembly ................................................................................ 26
Replacement Parts ..................................................................... 29

Spare Parts ......................................................................................... 29

Ordering Parts .................................................................................... 29

Exploded Views and Parts Lists.......................................................... 30

KC-5 and KC-8 Exploded View Drawing .................................. 30

KC-5 and KC-8 Parts List ......................................................... 31

Summary of Contents for KINNEY KC Series

Page 1: ...001807 0000 Tuthill Vacuum Blower Systems tuthillvacuumblower com 800 825 6937 WARNING Do Not Operate Before Reading Manual Operator s Manual Tuthill KC Series Two Stage Rotary Piston Vacuum Pump Copyright 2017 Tuthill Vacuum Blower Systems All rights reserved Product information and specifications subject to change ...

Page 2: ...nney vacuum pumps and M D PneumaticsTM blowers and vacuum boosters in Springfield Missouri USA We bring 100 years of engineering experience and solid hands on care to help customers keep their processes running Your satisfaction is important to us so please take time to provide your Tuthill sales representative with performance feedback We love to hear from our customers Tuthill is a family owned ...

Page 3: ... and Lubrication 3 Oil Types 3 Specifications 4 Safety 5 Graphic Conventions Used in this Manual 5 Safety Instruction Tags 5 Safety Precautions for Rotary Piston Pumps 6 Installation 7 Mounting 7 V Belt 7 Discharge Piping 7 Vacuum Piping 7 Vacuum Gauges 9 Electrical Connections 9 General 9 Filling the Pump with Oil 10 KC 5 and KC 8 10 KC 15 10 ...

Page 4: ...Oil 14 Flooding 15 Oil Mist Eliminator 15 Stalling 17 Troubleshooting 18 Checking Pump Performance 19 Pump Leaks 20 Checking Process Equipment 20 Process Equipment Leaks 20 Leak Checking Techniques 21 Oil Contamination 21 Discharge Valve 21 Shaft Seal 22 Disassembly 24 Reassembly 26 Replacement Parts 29 Spare Parts 29 Ordering Parts 29 Exploded Views and Parts Lists 30 KC 5 and KC 8 Exploded View ...

Page 5: ...anual 1807 Rev B p n 001807 0000 Table of Contents KC 8C Exploded View Drawing 32 KC 8C Parts List 33 KC 15D Exploded View Drawing 34 KC 15D Parts List 35 KC 15L Exploded View Drawing 36 KC 15L Parts List 37 ...

Page 6: ...iv Table of Contents Manual 1807 Rev B p n 001807 0000 ...

Page 7: ...he KC series of compound high vacuum pumps covered by this manual consists of two basic pump groups models KC 5 and KC 8 KC 15 The pumps within each of the first two groups are identical except for the motor and V belt drive which differ in order to produce different rotational speeds Specifically models KC 5 and KC 8 are the same except that the KC 8 is driven faster Each Kinney KC pump is an air...

Page 8: ...ded discharge valve is located at the discharge side of the backing stage on the open head end of the pump An oil mist eliminator is mounted above the backing stage A sight gauge is provided for checking the oil level in the pump When the pump is operating at low inlet pressure the level should be in the center of the sight gauge The oil level will change with large changes in pump inlet pressure ...

Page 9: ...s one at the discharge of each stage through internal cored passageways leading to each pumping stage The oil from the backing stage reservoir lubricates and seals the backing stage whereas the oil from the high vacuum stage reservoir lubricates and seals the high vacuum stage At the end of the compression stroke the oil is forced out with the discharged gas and returns to the respective oil reser...

Page 10: ...47 L 0 8 qt 0 76 L 3 qt 2 84 L Inlet connection 1 in FNPT 1 in FNPT 2 in FNPT Discharge connection 3 4 in FNPT 3 4 in FNPT 1 1 4 in FNPT Pump shaft diameter 3 4 in 19 1 mm 3 4 in 19 1 mm 3 4 in 19 1 mm Approximate length 19 13 in 486 mm 19 50 in 495 mm 22 50 572 mm Approximate width 13 25 in 337 12 31 in 313 mm 18 06 459 mm Approximate height 16 19 in 411 mm 16 19 in 411 mm 25 75 654 mm Approximat...

Page 11: ...environment or cause the equipment to operate improperly NOTE N Indicates a procedure practice or condition that should be followed in order for the equipment to function in the manner intended SAFETY INSTRUCTION TAGS WARNING Do not operate without belt guard CAUTION Do not valve or restrict pump discharge opening Use oil mist eliminator when operating pump ensure adequate ventilation when dischar...

Page 12: ...harge is discharged to outside atmosphere Laws and ordinances may pertain to your local area regarding discharge of oil mist or vapor to atmosphere Check local laws and ordinances prior to operation of the pump with discharge to outside atmosphere Venting of the discharge of an oil mist eliminator to outside atmosphere is highly recommended Do not restrict the pump discharge in any way or place va...

Page 13: ... load that is with the pump gas ballast valve fully opened Recheck the tension of the V belts after the first 48 hours of operation DISCHARGE PIPING If desired connect discharge piping to the discharge fitting on top of the oil mist eliminator to vent or reclaim the exhaust gases When connecting the discharge piping use a dropout trap at the connection to the oil mist eliminator Otherwise condensa...

Page 14: ... and are available from Tuthill Vacuum Blower Systems Other types of connectors may be too hard and transmit vibration or they may be too soft and may exert considerable force on the pump and piping when collapsing under atmospheric pressure To ensure proper lubrication at initial start up pour a small amount of oil into the pump suction before connecting the inlet piping Make all inlet connection...

Page 15: ...ng and indicating the degree of contamination A high thermistor or thermocouple gauge reading may indicate that the pump is contaminated that the pump leaks or both A high McLeod gauge reading means that a real leak is present ELECTRICAL CONNECTIONS WARNING Disconnect pump from electrical power source prior to making repairs or adjustments to any electric component of the unit Check the operating ...

Page 16: ...tion port 2 Pour the remaining 7 8 qt 0 85 L of oil into the high vacuum stage oil fill port 3 Continue to pour the remaining oil into the discharge port of the pump until the oil level is approximately 1 8 in 3 2 mm below the top of the sight glass PRE START CHECKS 1 Check that the suction lines are tight and completely free of all foreign matter 2 Check that the pump has been filled with oil 3 C...

Page 17: ...11 Manual 1807 Rev B p n 001807 0000 04 OPERATION Figure 4 1 Pump Components ...

Page 18: ...c pressure by opening a vent valve Turn off the power to the pump motor NOTE N If the system does not have a pump isolation valve vent the system to atmospheric pressure to prevent oil from being drawn into the vacuum system Oil flooding of the pump cylinder could make restarting difficult Note that a solenoid operated air inlet vent valve is offered as an accessory on the KC 15 model This valve i...

Page 19: ...ully and operate the pump for about 15 20 minutes 3 Close the gas ballast valve fully and observe the pressure change in that time period The oil is clean when there is no further reduction in pressure SPECIAL REFRIGERATION SERVICE PUMPS Kinney offers high vacuum pumps that are specifically engineered for servicing refrigeration equipment which includes thorough vacuum drying degassing and fast le...

Page 20: ...re as well as other vapors present in the system will be drawn into the pump Some may be condensed and will collect in the backing stage oil reservoir contaminating the pump oil and causing poor pump performance Proper use of gas ballast will minimize the amount of condensate and reduce the frequency of oil changes Change the oil when it becomes contaminated with foreign matter or with chemicals T...

Page 21: ...inspection shows the oil mist eliminator element is blocked by foreign matter Pump backpressure as read at the inlet to the oil mist eliminator or the oil fill plug reads higher than 4 6 psig 27 57 41 36 kPa This indicates the element is contaminated Motor current exceeds the manufacturer s recommendations shown on the motor nameplate This indicates the element is contaminated Mist is discharged f...

Page 22: ...16 05 Maintenance Manual 1807 Rev B p n 001807 0000 Figure 5 1 Oil Return Line ...

Page 23: ...ating Pressure not Attainable Associated Process Equipment Vacuum Pump Virtual Leaks Leaks Operator Error Contamination Leaks Malfunctions Figure 5 2 Common Faults in Vacuum Systems STALLING If the pump stalls at any time it may be due to a loose belt lack of lubrication or foreign matter in the pump If the pump cannot be turned over by hand after it has cooled down clean the pump See Disassembly ...

Page 24: ...tone alcohol or either Pump down with vacuum pump overnight Process equipment leaks Leak check the process equipment See Process Equipment Leaks on page 20 Improper vacuum pump oil flow Clean the oil ducts Contaminated vacuum pump oil Change the pump oil See Changing the Oil on page 14 and Oil Contamination on page 21 Discharge valves malfunctioning Check the valves as described in Discharge Valve...

Page 25: ...ck into the pump Reduce pump inlet pressure below 10 Torr to allow collected oil to drain back through the integral check valve in the oil mist eliminator Table 6 1 Common Symptoms and Remedies CHECKING PUMP PERFORMANCE If the processing time increases or the ultimate pressure becomes poor with no recent changes in the process or in the system configuration test the pump to determine whether the t...

Page 26: ... may be squeezed into the equipment Check carefully around the head to cylinder joints securing bolts plugs shaft seal housing joints and generally any penetration into the vacuum pumping portion of the pump Check the shaft seal for mechanical defects such as a cracked carbon washer or hardened rubber components CHECKING PROCESS EQUIPMENT If the blank off test shows that the vacuum pump is functio...

Page 27: ... or vacuum sealing compound such as Loctite 515 Temporary gaskets may be fabricated from plastic sealing compound but do not make them too thick since the material may be squeezed into the equipment OIL CONTAMINATION If the pressure has been satisfactory for some time and then gradually increases this indicates oil contamination Clean up the oil by applying gas ballast or change the oil as describ...

Page 28: ...Remove the rotating portion of the shaft seal from the shaft This may require a heavy pull especially if the unit has heat bonded to the shaft In extreme cases it may be necessary to remove the open head or shaft seal housing to remove the seal 5 If necessary remove the seal seat from the pump 6 Check the mating seal faces on the stationary and rotating segments of the seal assembly They should be...

Page 29: ... p n 001807 0000 13 Replace the pump drive key and pulley Replace the V belt drive and tension it as described in Mounting on page 7 Replace the belt guard Test the pump per Checking Pump Performance on page 19 Figure 6 3 Shaft Seal Assembly ...

Page 30: ... seal retaining ring from the shaft b Remove the rotating portion of the shaft seal from the shaft This may require a heavy pull especially if the unit has heat bonded to the shaft In extreme cases it may be necessary to remove the open head or shaft seal housing to remove the seal c Remove the stationary portion of the shaft seal seal seat from the pump 8 Remove the shaft seal housing by removing...

Page 31: ...of the head 17 Remove the shaft and cams as follows a Remove the closed head cam if necessary by tapping the shaft through the cam using a lead mallet or hammer and wooden block b Remove the shaft with the open head cam attached Do not remove the open head cam unless replacement of the shaft or cam is necessary If cam removal is necessary press the cam from the shaft 18 If seal removal is necessar...

Page 32: ...ide pin toward the center wall Insert the piston and slide the pin into the pump On KC 15 models position the closed head piston with the inlet slots in the piston slide facing away from the discharge valve side of the pump Place the closed head slide pin over the piston slide with the scalloped edges up and the arrow cast into the slide pin pointing toward the discharge valve side of the pump Ins...

Page 33: ...n ring with AX Vacuum Oil Cover the retaining ring groove and the keyway on the shaft with plastic tape or by forming a thin piece of metal over the shaft Coat the shaft and the metal cover with oil Carefully push the rotating portion of the shaft seal over the shaft by means of a pipe sleeve or a large washer Be careful not to damage the seal face or cut the rubber Remove the cover from the shaft...

Page 34: ...28 08 Reassembly Manual 1807 Rev B p n 001807 0000 ...

Page 35: ...hese items be maintained in stock for use as necessary It is also recommended that sufficient AX Vacuum Pump Oil be kept on hand for at least one oil change as well as a can of Loctite 515 for sealing leaks An accurate vacuum gauge such as Kinney McLeod gauge Model TD be obtained for checking pump performance ORDERING PARTS When ordering parts order them by item number and description and specify ...

Page 36: ...S LISTS KC 5 and KC 8 Exploded View Drawing KC 5 KC 8 Pump RPM 638 1022 Motor HP kW 0 33 0 25 0 50 0 37 Oil Capacity qts liters 0 8 0 76 Forced Drain w open suction qts liters 0 85 0 80 Use Loctite 515 vacuum pump sealant for assembly For best performance use only AX vacuum pump oil ...

Page 37: ...FT 1 12 DISCHARGE VALVE KIT 1 13 BEARING SPACER KIT 2 14 SIGHT GLASS ASSEMBLY 1 15 GASKET 1 16 O RING 2 17 SEAL CENTER WALL 1 ITEM NO DESCRIPTION QTY 18 SHAFT SEAL 1 19 RETAINING RING 1 20 KEY 2 21 KEY 1 22 GAS BALLAST VALVE 1 23 DRAIN COCK W SEAL 2 24 GASKET 1 25 CAP SCREW HEX HEAD 1 26 DOWEL PIN 6 27 CAP SCREW HEX HEAD 41 When ordering parts use the item number shown plus the model and serial nu...

Page 38: ...d View Drawing Free Air Displacement CFM L sec 8 3 78 Pump Rotative Speed RPM 1022 Ultimate Pressure Torr mbar a 005 007 Motor HP kW 0 75 0 56 Oil Capacity qts liters 0 8 0 76 Use Loctite 515 vacuum pump sealant for assembly For best performance use only AX vacuum pump oil ...

Page 39: ...16 BEARING SPACER SET 2 2 17 SIGHT GLASS ASSEMBLY 1 1 18 GASKET 1 1 19 O RING 2 2 20 SEAL CENTER WALL 1 1 ITEM NO DESCRIPTION BRAKE FLUID SERVICE QTY REFRIGERATION MINERAL OIL QTY 21 SHAFT SEAL 1 1 22 RETAINING RING 1 1 23 KEY CAM 2 2 24 KEY DRIVE SHAFT 1 1 25 DRAIN COCK W SEAL 2 2 26 GASKET 1 1 27 CAP SCREW HEX HEAD 1 1 28 DOWEL PIN 4 4 29 CAP SCREW HEX HEAD 37 37 30 OIL MIST ELIMINATOR 1 1 30A E...

Page 40: ... Pump Rotative Speed RPM 572 Ultimate Pressure Torr mbar a 005 007 Motor HP kW 1 0 75 Oil Capacity qts liters 3 0 2 84 After normal oil drain start pump to force out residual oil Then refill both stages with quantities shown above Use Loctite 515 vacuum pump sealant for assembly For best performance use only AX vacuum pump oil ...

Page 41: ...E 265 DRAIN COCK SPECIAL 2 2 26 COUPLING 3 3 27 NIPPLE 2 2 28 NIPPLE 29 ELBOW 1 1 ITEM NO DESCRIPTION BRAKE FLUID SERVICE QTY REFRIGERATION MINERAL OIL QTY 30 PIPE PLUG 1 1 31 SEAL WASHER 1 1 32 CAP SCREW HEX HEAD 1 1 33 DOWEL PIN 6 4 34 CAP SCREW HEX HEAD 36 36 35 CAP SCREW HEX HEAD 20 20 36 CAP SCREW SOCKET HEAD 2 2 37 LOCK WASHER 2 2 38 MACHINE SCREW 2 2 39 LOCK WASHER 2 2 40 OIL MIST ELIMINATO...

Page 42: ... Pump Rotative Speed RPM 572 Ultimate Pressure Torr mbar a 005 007 Motor HP kW 1 0 75 Oil Capacity qts liters 3 0 2 84 After normal oil drain start pump to force out residual oil Then refill both stages with quantities shown above Use Loctite 515 vacuum pump sealant for assembly For best performance use only AX vacuum pump oil ...

Page 43: ...CK 1 1 270 DRAIN COCK W O RING 1 1 280 COUPLING 3 3 290 NIPPLE 2 2 300 NIPPLE 1 1 310 ELBOW 1 1 ITEM NO DESCRIPTION BRAKE FLUID SERVICE QTY REFRIGERATION MINERAL OIL QTY 320 PIPE PLUG 1 1 330 SEAL WASHER 1 1 340 CAP SCREW HEX HEAD 1 1 350 DOWEL PIN 6 4 360 CAP SCREW HEX HEAD 36 36 370 CAP SCREW HEX HEAD 20 20 380 CAP SCREW SOCKET HEAD 2 2 390 LOCK WASHER 2 2 400 MACHINE SCREW 2 2 410 LOCK WASHER 2...

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Page 46: ...oid warranty Installation and transportation costs are not included and defective items must be held for Seller s inspection and returned to Seller s Ex works point upon request THERE ARE NO WARRANTIES EXPRESSED IMPLIED OR STATUTORY WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS OF PURPOSE After Buyer s subm...

Page 47: ...ze Length Serial No Type of Lubrication Start up Date Pump RPM Operating Vacuum Pump Sheave Diameter Any Other Special Accessories Supplied or in Use Motor Sheave Diameter Motor RPM HP NOTES IMPORTANT All blowers manufactured by Tuthill Vacuum Blower Systems are date coded at time of shipment In order to assure you of the full benefits of the product warranty please complete tear out and return th...

Page 48: ...illvacuumblower com Manual 1807 Rev B p n 001807 0000 Technical Support 1 877 955 TECH 8324 Service Repair or Product Sales I N T ERNATIONAL QUALITY STAND A R D REGISTERED VACUUM BLOWER SYSTEMS TUTHILL CORPORATION Copyright 2017 Tuthill Vacuum Blower Systems All rights reserved Product information and specifications subject to change 1 18 ...

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