Price $5.00 DUROFLOW@ D-9-620 1st Edition BO11O Supersedes SERIES 4500 BLOWERS SERVICE MANUAL # COOPER Gardner-Denver Industrial Machine~ DUROFLOW. 45 Series Blowers Table of Contents Section One: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2 Section Two: Suggested Section Three: Teardown Section Four: Policy Replacement Items Section Five: Major Parts Cleanup Procedures.. Section Six: Major Parts Inspection Section Seven: Assembly Procedure Section Eight: SpurGear Blowers Section Nine: Operating Limitations Section Ten: Lubrication Section Eleven: Parts Lists, Sectional Section Twelve: Troubleshooting Section Thirteen: Warranty Equipment Procedure and Supplies for a Major Overhaul . . . . . . . . . . . . . . ...3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19 Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20 and Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . ...21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25 SECTION ONE Introduction and bottom This manual was prepared as a guide for the person involved in the maintenance or overhaul of DuroFlow@ 45 Series Blowers utilizing splined gears. There are two versions, rotor shafts and timing one of which uses spur gears and the other, helical gears. The helical gear version In the horizontal-right is mounted The VT and HL configurations are identical the position is the latest in the evolution of the unit. configuration, the drive rotor of the idler rotor. of the oil breather (HR) to the right except and the oil filler for plug and a change in the mounting plate in the HL. Likewise, the VB and the HR configurations correspond to of DuroFlow blower technology. It differs from its predecessor, the spur gear version, only in the gear tooth each other with the same differences configuration The VT-HL differs from the VB-HR in having a different oil flinger on the drive end which is mounted on the drive shaft in the VB-HR version rather than on and the addition of a Belleville spring behind one timing gear. On the helical gear blower, rotor timing is accomplished by varying the position of a lock nut moving one timing gear axially pressure of the Belleville spring washer. longitudinal movement the idler gear changes tween the two rotors. the angular the proper rotors. This gear angular flinger is more deeply dished in the VB-HR versions. to be- Since the VT version various configurations, In the spur gear version, by selective assembly. matched to a particular relationship rotor timing is accomplished manual is concerned which is version, between primarily currently the two end fiinger is the most common of the the illustrations and the tear- should keep in mind preceding paragraphs. In addition, with the helical in production. Section Eight covers the differences in teardown reassembly procedure for the spur gear version. than thegear down and reassembly procedures in this manual refer to the VT configuration. The person involved in overhauling one of the other versions of the blower A particular set of gears is set of rotors in order to achieve relationship HL. the idler shaft as in the VT-HL. Both oil flingers are identical in the VT-HL version, whereas the drive end against the This slight of the drive gear in relation as the VTand versions, if the overhauling it is advisable differences either noted the to use a holding HL in the or HR fixture to secure the blower to the workbench. This can be obtained from DuroFlow or it can be fabricated as in and Fig. 4. Each of the four sizes of 45 Series configurations designated blowers by the position It is suggested that the appropriate sections of this manual be read and fully comprehended before any has four of the drive specific service operation is attempted. Further, the importance of a clean and adequately outfitted workshop cannot be overemphasized. The success of shaft as viewed from the drive end. The most common configuration, designated vertical-top (VT), has the drive rotor above the idler rotor and the airbox inlet and discharge ducts are at the sides. In the verticalbottom (VB) configuration, the drive rotor is mounted below the idler rotor. In the horizontal-left (H L)configuration, the drive rotor is to the left of the idler rotor and the airbox inlet and discharge any major recognition Blowers modifications service effort depends upon fact that virtually every part contained in the assembly is highly precise, and hence, is vulnerable to the damaging effects of dirt, moisture and rough handling. ducts are at the top IMPORTANT In mid-1981, blower of the NOTICE to the 45 Series end plates were made that are not shown in the text of this manual. now require only one conventional breather cap. This difference When properly mounted, the air breather ports on modified longer require breather caps. If these vent ports are threaded, will not affect service procedures. blowers are always facing downward, and no a breather vent will be inserted. DO NOT PLUG OR OBSTRUCT THESE AIR VENT PASSAGEWAYS!! The oil sump breathing is now accomplished oil fill hole, and the blowers’ only breather through the oil fill port. A hexagonal cap is placed 2 in this bushing bushing is inserted to vent the oil sump. into the SECTION TWO Suggested Equipment and Supplies for a Major Overhaul A. Sturdy 3’ x 6’ workbench, equipped width, turret type machinist’s vise. B. 10 ton, 2-jaw, 5-1 /2” reach puller, with a 5“ jaw such as Snap- On CG-270. c. Wrenches and PI iers. 1. 12“ adjustable (“Crescent” 2. 9/16“ six-or twelve-point bination. type). box/open end com- 3. 3/8’ orl /2” square drive socket tools. a. Ratchet handle. b. 3“ to 6’ extension c. d. 9/16’ six-or twelve-point socket. Torque wrench, 1 ft-lb graduations to 50 ftIb [7 mkg], such as Snap-On Nos. TE-50F or STEEL bar. TE-51 F Torqometers. I 4. 3/4” square drive socket tools. a. Ratchet or sliding tee handle. b. c. 1-13/16’ six-or twelve-point socket. Torque wrench, 5 ft-lb graduations to 350 ft-lb [50 mkg], such as Snap-On No. TE-352 Torqometer. Q ~ 1 L ———= - COLD DRAWN SEAMLESS TUBING 2“ I ~; c! I ! ~ i’– I I I zWELD ‘~ I J J &2.82”& FIGURE 3 OIL SEAL INSTALLATION TOOL O. D, 0.180 WALL 1/2” THICK MILD PLATE r—2“-7sTEEL J 252,, MATERIAL 3“ WELD ——. Iy ‘\ /:’ T 5. Large internal snap ring pliers, Tru-Arc No. S-6700. such as Waldes D. Hammers. 1. 24 ounce ball or cross peen. 2. 3 pound plastic faced or rawhide mallet. E. Chisels and punches. 1. 5/8” edge width flat chisel, blunted. 2. 5/16” shank diameter pin punch. 3. 118” point center punch. F. Cleaning and deburring tools and supplies. solvent, 1. Decreasing tank of chlorinated I I I ,1 Ld I I _ 1.64” FIGURE 2 BEARING SLEEVE INSTALLATION TOOL such as perch lorethylene. 2. 12 clean shop rags. 3. Stiff, natural bristle scrub brush. 4. Wire wheel or brush. 5. 1-1 / 2“ edge width gasket scraper. 6. 8“ half round file, smooth or second cut. 7. Assorted silicone carbide or aluminum abrasive paper, in 240, 320 and 400 grits. G. Measuring oxide instruments. 1. Micrometer caliper, O“ to 0.001” [0 to 25 mm graduated 1“, graduated in 0.01 mm]. in 2. Depth micrometer, 1“ to 2“, graduated [25 to 50 mm graduated in 0.01 mm]. 3. Dial test graduated in 0.001” 1. with magnetic clamp base holder. Service Specs CC and SE (See Recommendations, Sec. Ten). 2. 1 pound fresh assembly lubricant, molybdenum disulfide grease. to A.P. I. such block as appropriately plate to work approximately Special tools and fixtures 3. Blower NOTE: zontal chased 3“ x 6“ x 1 /2” to tool (Figure blowers. from If preferred, DuroFlow 3). this can be pur- (See Item 40, Section tool (Figure 5). I I 7 3“ WELD MODE L I 4504 I - HOT ROLLED A“ 1.75 I STEEL B“ I c“ Z75 I 6.25 I ,, 1 .1 ,, 1 E HOLDING FIGURE 4 FIXTURE FOR 4500 SERIES BLOWER to bench. holding fixture (Figure 4). Holding fixture is needed only for hori- Eleven). 4. Bearing installation MATERIAL x (see sketches). tool (Figure’2). 1. Rotor sleeve installation 2. Oil seal installation Lubrication sized mounting 1-1 /2” 4. Awl. J. conforming approximately C-clamps blower 3. Wooden 1“ thick. 4. 12“ x 1 /2” feeler stock, 0.002” to 0.015“ in 0.001” increments, [0.04 to 0.40 mm], 2 strips of each, such as Starrett Series 667. H. Lubricants and compounds. 1. 2 quarts fresh motor oil, items. blocks, 3-1/2’’ xlo’. 2. Two sturdy indicator (lever contact arm type), in 0.0005” or 0.001” [0.01 or 0.02 mm], and equipped Miscellaneous 1. 3 wooden .—— ‘2A< FIGURE 5 BEARING INSTALLATION TOOL SECTION THREE Teardown Procedure A. Preparation. Before beginning the teardown sequence, the oil should be drained from the unit. It is also suggested that the usual accumulation of sludgy or encrusted material be removed from the exterior. This can best be accomplished by scouring with a stiff bristle brush and soapy water, followed by a pressure rinse with water. An acceptable alternative is steam cleaning, if the equipment is available. Because all salvable parts are made of cast iron (or other ferrous alloy), virtually any heavy duty, chemical cleaning agents—EXCEPT those which are ACIDIC—are acceptable. It should be noted, however, that when water (or steam) is used in the cleaning process, the unit must be disassembled pressed faces. immediately, air to prevent and blown dry with rusting of machined B. Teardown sequence. NOTE: Numbers in parentheses numbers drawings ( of the unit into FIGURE 7 REMOVING BREATHER CAPS FROM GEAR END PLATE ) refer to key in sectional and exploded on pages 22 and 23. 1. Separation comsur- basic assembly NOTE subassem- blies. a. All screw standard Securely fasten the unit to the workbench, gear end facing out, using the mounting or holding fixture and C-clamps (see Fig. 6). right-hand on the blower Remove the 2 breather caps from end plate (7) (see Fig. 7). c. Remove eight pipe plugs. Remove the 14 thru-bolts d. e. are threads. b. screws the gear (4) and 2 cap (5) from the gear end cover (l). Remove the gear cover (1) from the gear end plate (7). NOTE: The gasket end BLOWER SECURED threads plate seam used to seal the cover/ tends to bond tightly to FIGURE 8 FOUR CAPSCREWS WITH SPACERS BEING TEMPORARILY REPLACED IN GEAR END PLATE FIGURE 6 TO WORK STAND WITH “C” CLAMPS 5 both surfaces. After bolt and screw moval, it. is usually necessary to drive the gear cover using and blunted chisel. f. h. reoff gears appear to be reusable, it to make index marks on the gears to facilitate the ball peen hammer rotor timing upon reas- sembly. This can best be done by making small punch marks on the ends of meshing gear teeth with a pin punch and hammer Temporarily replace four of the cap screws (4), two in each housing half, to retain the (see Fig. 10). gear end plate (7) during subsequent operations. NOTE: Each cap screw must be bushed with a spacer to prevent bottoming in the 9. If the timing is advisable absence of the gear cover (see Fig. 8). If the timing gears appear to be undamaged, it is advisable to check the gear backlash before removing gears to determine they can be reused (see Fig. 9). whether (1) Mount magnetic base dial indicator on gear end plate with arm extending toward drive gear. (2) Lock idler rotor stationary by wedging a feeler gage between idler rotor and end plate. (3) Place the tip of the indicator arm at approximately the center of the contact surface on a tooth of the drive gear. (4) Rock the drive gear by hand and read the total movement to the nearest .0005 in. [.012 mm]. (5) Rotate the idler rotor 90° measurement three times. and (6) Permissible is .0025 to gear backlash FIGURE 10 INDEX MARKS ON ENDS OF GEAR TEETH i. repeat .0055 in. [.064 to .141 mm]. NOTE: If backlash is outside specified limits at this point, it does not neces- j. Place wood block between idler rotor lobe and edge of inlet-discharge opening to prevent rotor from turning. Loosen but do not remove the flexlock nut from each rotor shaft. Move to drive end of blower. Locate the tang of the spider washer (21) which was bent into slot of lock nut (22). Bend the tang out of the lock nut slot using pin punch and hammer (see Fig. 11). sarily mean gears are unusable because the excessive play could be caused by worn bearings. However, if backlash is within limits and there is no apparent damage, the gears may definitely be k. Chock blunted reused. FIGURE 9 CHECKING TIMING GEAR BACKLASH WITH DIAL INDICATOR 6 drive rotor flat chisel with wood and hammer, block. Using loosen lock 1. nut (see Fig. 12). Use caution age rotor shaft with chisel. Remove lock nut and spider discard not to damwasher r. and both as they will not be reused. Remove the drive end plate from the remainder of the assembly using soft faced mallet to loosen end plate from dowel pins in housing halves (see Fig. 14). CAUTION: The about 40 pounds. drive end plate weighs Use care not to drop it. FIGURE 12 USING BLUNTED FLAT CHISEL AND BALL PEEN HAMMER TO LOOSEN LOCK NUT m n. Remove washers s. washer assemblies (5) from the drive end cover (30). Remove the drive end cover. It may be necessary to use blunted flat chisel and hammer to loosen cover from end plate. o. Remove bearing (see Fig. 13). P. Chock idler rotor with wood block. flexlock nut (27) from drive end Remove of idler shaft. Remove oil flinger (29) and clamp (28) from idler rotor shaft. washer q. FIGURE 14 USING SOFT FACED MALLET TO LOOSEN DRIVE END PLATE the 14 cap screws (18), 14 lock (6), and two cap screw and lock t. Remove the flexlock nut (44) from the gear end of the drive rotor shaft. Remove the timing gear from the drive rotor using the gear puller (see Fig. 15). Make sure oil flinger (29) is turned so as not to interfere with gear being removed from the spacer (20) from drive shaft drive shaft. FIGURE 15 USING PULLER TO REMOVE TIMING GEAR u. v. w FIGURE 13 REMOVING BEARING SPACER FROM DRIVE SHAFT 7 Remove the Belleville spring (48) and dis- card as it will not be reused. Separate the drive rotor from the gear end plate (see Fig. 16). Remove the two cap screws and spacers holding the upper housing half (12) to the gear end plate and remove the upper ing half. x. y. z. aa. bb. cc. dd . ee. Remove the flexlock nut (44) from rotor shaft. Remove the oil flinger (29). replaced as a matter of service policy. (1) Securely fasten the rotor in the vise, using 2 wood blocks to prevent marring of the contoured surfaces. hous- the idler (2) Remove the seal ring (13) from the drive end sleeve (14), using the awl to pry apart the interlock, and then break the ring from underneath. Use gear puller to remove the idler gear (42) from the idler rotor (32). Remove the idler rotor from the gear end plate. Remove holding the two cap screws and spacers the gear end plate to the lower housing half (39). Remove the gear end plate housing half. from (3) Remove the seal ring (13) from the gear end sleeve (11), as in Step 2. (4) Remove shims (15) from rotors. (5) Only as required in accordance with the guidelines given under PREFACE, remove the sleeve(s) from the rotor shaft(s) the lower CAUTION: The gear end plate weighs about 35 pounds. Use care not to drop it. Loosen the C-clamps and invert the lower housing half on the workbench. Remove the four cap screws (37) and lock washers (38), and separate the plate (40) from the lower housing using the gear puller. b. mounting End plate subassembly. PREFACE: Since all seals and bearings should be replaced during overhaul as a matter of service policy, both end plate subassemblies half. must be completely disas- sembled internally. (1) Remove the 2 retaining rings (26) from their respective bearing sockets, using the snap ring pliers. (2) Invert the end plate on the work bench, and set on 2 oak blocks, 3-1 /2” clearance between so as to provide the plate and bench, and to clear the edges of the bearing sockets. (3) Remove the drive rotor bearing (9) or(l 7) from its socket, using the ball peen hammer and pin punch. (4) Remove the drive rotor oil seal (10) from its socket, as in Step 3. (5) Remove the idler rotor bearing (9) or(17) from its socket, as in Step 3. (6) Remove the idler rotor oil seal (10) from its socket, as Step 3. c. ponent a. of the subassemblies into com- parts. shou Id always Rotor subassembly. PREFACE: Except in unusual end plugs in each rotor casting removed or replaced. Rotor sleeves need only cases, the 4 d. need not be be removed should always be removed be replaced service policy. Drive end cover. (1) Place cover on two wood as a matter blocks of gasket side up. With hammer and punch drive out the seal (25). Discard seal as it will be replaced. there is no reason to remove (2) Normally, the two dowel pins (34) which are pressed into the cover. from their respective shafts for the purpose of rotor or sleeve salvage. The 2 iron seal rings carried in the rotor sleeves pins (34) and 2 ferrules (35) in each housing half end surface need not be removed or replaced. However, the 2 “O” rings (36) carried on the ferrules of each housing half FIGURE 16 REMOVING DRIVE ROTOR FROM GEAR END PLATE 2. Separation Housing half subassembly. Except in unusual cases, the 4 dowel and 8 SECTION FOUR Policy Replacement Items It is suggested that the following parts be replaced each time the 45 Series blower is disassembled regardless of apparent merely reflects sound of these parts cannot or measured service policy be justified condition. This in that the reuse savings when possible consequences are considered. It is not necessary to order these parts individually, as DuroFlow offers a factory service parts kit for the 45 Series, splined shaft blower. on the basis of cost Description Qty. Per Unit Qty. Per Unit Item No. Roller Bearing 2 22 Lock Nut 1 10 Oil Seal 25 13 Seal Ring 4 4 Oil Seal Gasket 1 2 15 Shim .002—.003— 0 Ring 4 17 .005—.007—.01 Ball Bearing 21 Lock Washer Item No. Description 9 31 36 46 As O” Required 2 Gasket Belleville 48 2 1 Spring 1 SECTION FIVE Major Parts Cleanup Procedures A. Rotors. 1. Dip in decreasing tank agitating and brushing to remove grease and oil. 2. Sandblast or wirebrush as necessary to remove scale from rotor lobes. If sandblasting, mask bearing sleeves, bearing spacers, and shafts with rubber hose or tape to prevent erosion. 3. Lightly wet polish the bearing sleeves, bearing spacers, and rotor shafts with crocus cloth. 4. Any burrs on rotor or shaft should be removed with a file. tank and blow dry with 5. Dip again in decreasing compressed air. and reused im6. If rotor is not to be inspected mediately, dip in oil or rust preventative solution and seal in a clean plastic bag for storage. solution age. and seal in clean plastic C. Housing halves. 1. Dip in decreasing tank agitating to remove grease and oil. bag for stor- and brushing 2. Sandblast or wirebrush as necessary to remove scale. 3. Wet polish the machined concave surface with 240 grit abrasive paper. 4. File burrs on machined surfaces. 5. Dip in decreasing tank and blow dry with com- pressed air. Use particular care to insure that all foreign matter is purged from oil passages. 6. If housing is not to be inspected and reused immediately, dip in oil or rust preventative solution and seal in clean plastic bag for storage. B. End plates. 1. Dip in decreasing tank agitating and brushing to remove grease and oil. 2. Sandblast or wirebrush as necessary to remove scale. If sandblasting, place plugs in seal ring bores to prevent erosion during blasting. 3. Lightly wet polish the seal ring bores with 400 grit abrasive paper. 4. Remove burrs with file. tank and blow dry with com5. Dip in decreasing pressed air. 6. If end plate immediately, is not to be inspected dip in oil or rust and reused preventative D. Timing gears. 1. Dip in decreasing tank to remove grease and oil. 2. Wirebrush as necessary to remove scale. 3. Remove nicks and burrs with file. 4. Dip in decreasing tank and blow dry with compressed air. 5. If gears are not to be inspected and reused immediately, dip in oil or rust preventative solution and seal in clean plastic E. Covers. 1. Dip in decreasing bag for storage. tank agitating to remove grease and oil. and brushing F. Mounting plate, flingers, and external hardware. 1. Dip in decreasing tank to remove grease and 2. Scrape gasket surface to remove any remaining pieces of gasket. 3. File any burrs on gasket surface. 4. Dip in decreasing tank and blow dry with compressed air. 2. oil. File burrs from mounting surfaces of mounting plate. 5. If covers are not to be inspected and reused immediately, dip in oil or rust preventative solution and seal in clean plastic bag. 3. SECTION If parts are not to be reused immediately, in clean plastic bag. store SIX Major Parts Inspection Procedures A. Rotors. The rotors degeneration occurred. cylindrical are usually salvable of the contoured or end surfaces checked has be checked for uniformity with end plates, housings, rotor lobe length and width contact 3.982-3.986 4512 5.978-5.982 mm] 7.372-7.374 in. mm] 7.372-7.374 11.971-11.977 7.372-7.374 in. [304.07 -304.22 mm] B. End plates. The end plates are usually box and seal ring mm] smoothness. bent, but can be straightened so that the mounting holes line up, it may be reused. External hardware mm] can be reused if the planar air appear undam- G. Flingers. Usually salvageable, disturbance is allowable. If seizure of the rotor group had occurred during operation, the end plates should be checked for cracks. damage around be replaced. halves. halves are usually salvable the threads are good and shaft which should always be replaced as a matter of service policy. The oil gage plug and breather filters should also be replaced. usually found without more extensive damage to surrounding areas. Ring bore condition, however, is critical. No visible evidence of surface finish housing provided the heads of screws and plugs are not too severely deformed. Exceptions to this are the spider type lock washer and external lock nut on the drive aged. As with the rotors, moderate localized gouging of the air box surface is allowable but is not The The seal bore of be examined for F. Mounting plate and external hardware. The mounting plate is nearly always salvable provided it is not cracked or severely bent. If it is mm] in. [187.25 -187.30 bore surfaces there are no wearing surfaces. the drive end cover should in. [187.25 -187.30 salvable mm] in. [187.25 -187.30 spherical E. Covers. The gear end and drive end covers are nearly always salvable provided there are no cracks since in. [187.25 -187.30 salvable if the meshof profile degenera- tooth wear has gone beyond acceptable limits, it is necessary to check the backlash when the pump is reassembled. for advice): Width 8.976-8.982 in. [228.00 -228.14 mm] c. Housing be during can be tolerated. This produces a tooth contact pattern that is characteristically elliptical and somewhat more polished than that of the surrounding tooth surface. To determine whether gear and smoothness 7.372-7.374 in. [151.84 -151.94 4509 As crown so that small errors in axial rotor alignment or with each other, the should be measured. factory [101.14 -101.24 4506 had occurred tion. The gear teeth are cut with a slight The following table gives lengths and widths for the various 45 series models (If specifications outside 4504 if seizure halves should operation. and should be free of burrs, eruptions, and other irregularities. If there is evidence of rotor contact these limits, Models Length for cracks appear undamaged. the housing D. Timing gears. The timing gears are usually ing teeth show no evidence Occasionally, a hard object accidentally passes through the blower causing localized gouging of the lobes. This is not necessarily grounds for immediate rejection unless the gouging takes place on the tip sealing vanes. Rotor end surfaces should air box surfaces with the end plates, if no significant if the 10 but if any cracks the center hole exists or surface they should SECTION SEVEN Assembly Procedure A. b. Preparation. All metallic spirits ings parts should to remove from gested residual deburring that operation all also eliminate any traces It to be used undergo solvent in clean operations. tools yet another Following be rinsed immersed dirt or fil- is also sug- a solvent oil seal installation wash, so as bal I peen hammer to drive the seal securely onto its seat. (2) Install another presoaked oi I seal in the to wash, the parts and tools should drive socket (1) above. air. rotor shaft seals (1O) and (25) shou Id be blower fora period of at least two (2) hours prior to installation in the end plates. This will allow the to as in Step bearing hammer prevent instal Iation tool and ball to drive the bearing tightly peen onto elastomers to absorb accelerated early wear. its seat. sequence. NOTE: Install roller bearings in gearend plate and ball bearings in drive end plate B. Reassembly oil of the end plate, (3) Install the idler bearing (9) or(17) in the idler socket of the end plate using the in fresh motor oil of the type used in the sufficient oil seal (10) on the tool and instal I the seal in the id Ier socket of one end plate (7) or (33), metal side down, using the reassembly source of contain i nation. be blown dry with clean compressed The elastic of in the End plate subassembly. (1)Place one presoaked mineral 1. Rebuilding component parts into basic subassemblies. a. Rotor subassembly. If the sleeves were removed as described in (drive end plate is thicker). (4) Install the drive bearing (9) or (17) in the drive socket of the end plate, as in Step Section Ill, proceed as follows: (1) Lightly coat the gear end rotor shaft and the bearing sleeve (11 ) bore with assem- (3) above. (5) Install the 2 retaining rings (26) in their respective bearing sockets, bevelled bly lubricant. (2) Install the bearing sleeve side out, using the snap pliers (see Fig. 17). Make certain the snap rings are properly seated in their grooves. (11) on the gear end rotor shaft, using the sleeve instal Iation tool and ball hammer to drive the sleeve tightly rotor peen onto its seat. NOTE: The face of the seal ring end of the sleeve is notched out in two places to provide clearance for tips of the mating rotor lobes. Therefore, the sleeve must be installed in such a position that the valley sections of its rotor are both totally encompassed by a notch on both sides. (3) Lightly coat the drive end rotor shaft and the bearing spacer (14) bore with assembly lubricant. (4) Install the bearing spacer (14) on the drive end rotor shaft, as in Step (2) above. If sleeves were not removed, or after rein- FIGURE 17 INSTALLING RETAINING RING stalling them: (5) Coat the seal ring groove with assembly lubricant. Install and couple the seal ring (13) on the bearing c. sleeve (1 1). (6) Install and couple the seal ring (13) on the bearing spacer (14), as in Step (5) above. Housing half subassembly. Assuming that the 4 dowel pins (34) and 2 ferrules (35) were not removed, install the 2 “O” rings (36) on the ferrules d. 11 Drive end cover (30). (35). Invert cover and place on wood blocks NOTE: The lower housing half differs from the upper housing half in that the lower half has one through hole from end to end while gasket side down. Wipe excess oil from O.D. of presoaked seal (25). Place seal in its bore with metal face up and mallet to seat securely. tap with b. the upper half has two through holes. Invert assembly and secure mounting c. to workbench with “C” clamps. The clearance between the air box surface plastic plate of the drive end plate and the drive end of the rotors is controlled by placing shims of the required number and thickness on the drive end of each rotor between the bearing spacer and the inner race of the ball bearing. The procedure for determining the shim thickness required for each shaft is as follows. Using depth micrometer, measure the distance from the planar air box surface to the inner race of the double row ball bearing reading to the nearest .0005 in. (see Fig. 17A). For the corresponding shaft, measure from the outer end of the bearing spacer to end of the rotor lobe reading to the nearest .0005 in. (see Fig. 17B). The first measurement minus the second measurement plus the appropriate drive end clearance specified in the table below is the total shim thickness required. (If specifications are outside these limits, contact factory.) FIGURE 17A MEASURING FROM AIRBOX SURFACE TO INNER RACE OF BALL BEARING Drive End 2. Final a. assembly. Model Place lower housing bench with cylindrical Place mounting align holes, screws Torque plate half assembly (39) on housing Gear End Minimum Clearance Clearance on air boxsurfacedown. (40) Minimum half, 4504 .005 in. [.127 mm] .006 in. [.152 mm] 4506 .005 in. [.127 mm] .007 in. [.178 mm] .010 in. [.254 mm] .007 in. [.178 mm] .016 in. [.406 mm] 4509 4512 secure with four cap (37) and four lock washers (38). cap screws to 50 to 60 ft-lb [7.0 to and d. 8.3 mkg]. .014 in. [.356 mm] Assemble the required shim stacks, reading the micrometer caliper to the nearest 0.0005” across the total lamination of shims to be used, so as to reduce additive FIGURE 17B MEASURING FROM END OF BEARING SPACER TO END OF ROTOR LOBE error. NOTE: Always shims necessary use the to least obtain number the FIGURE 18 ASSEMBLING SHIMS TO DRIVE END OF DRIVE ROTOR SHAFT 12 of required stack e. f. thickness, as this reduces the ap- j. Install the upper housing half to the drive parent loss later produced by retaining nut compression. Install the assembled shim stacks (15) on end plate. Ferrule with “O” ring must mate with counterbored hole in end plate. Secure with two cap screws (18) using a 1 /2-13 nut their respective Fig. 18). spacer under the head of each cap screw (see Fig. 21). Torque cap screws to approximately 30 ft-lb [3.9 mkg]. drive end rotor shafts (see Install the drive end plate to the lower housing half with two cap screws (18) using a 1 /2-13 nut spacer under the head of each cap screw (see Fig. 19). Torque cap screws to approximately 30 ft-lb [3.9 mkg]. FIGURE 21 TWO CAPSCREWS WITH SPACERS USED TO TEMPORARILY FASTEN UPPER HOUSING HALF TO DRIVE END PLATE k. FIGURE 19 TWO CAPSCREWS WITH SPACERS USED TO TEMPORARILY FASTEN DRIVE END PLATE TO LOWER HOUSING HALF. g. Brush the bearing h. of both rotors with assembly lubricant. Install the idler rotor to the drive end plate. spacers i. Use extreme care in starting the seal ring in the bore as the ring can easily be broken. Assemble the drive rotor to the end plate Brush the bearing of both rotors stall gear sleeves on the gear ends with end assembly plate using lubricant. care in- to avoid damage to the seal rings during assembly. Secure end plate to housings using six cap screws with 1 /2-13 nut spacers (see Fig. 22). Torque screws to approximately 30 ft-lb on the drive ends [3.9 mkg]. 1. Lubricate threads with assembly on drive end of each shaft lubricant. FIGURE 22 SIX CAPSCREWS WITH SPACERS USED TO TEMPORARILY FASTEN GEAR END PLATE TO UPPER AND LOWER HOUSING HALVES 13 m. Assemble clamp washer (28) and oil flinger (29) to drive end of idler shaft (see Fig. 23). Be sure that oil flinger cave side out. is assembled punch, tighten lock nut sufficiently press shim stack (see Fig. 25). con- FIGURE 23 ASSEMBLING CLAMP WASHER AND OIL FLINGER TO DRIVE END OF IDLER SHAFT n. Assemble flexlock nut (27) to to com- FIGURE 25 TIGHTENING LOCK NUT TO CHECK DRIVE END CLEARANCE q. drive end of between idler Check drive end plate to rotor lobe clear- nut to each rotor with feeler gages (see Fig. 26). (Drive end clearance for each model is specified in table following Step o. 300 ft-lb [42 mkg] (see Fig. 24). Assemble bearing spacer (20) to drive end c of Final Assembly procedure on page 12). If clearance is not within specified limits for P. of drive shaft. Assemble lock nut (22) to drive end of drive each rotor, remove the drive end plate and add or remove shims as necessary to adjust shaft clearance. ance. idler shaft. rotor lobe and prevent body. Place wood rotor with inlet from chamfer Using block or discharge turning. facing hammer and duct Torque toward blunted ance to pump flat r. for Reassemble When drive end temporarily remove taining and recheck clearance the snap clear- is correct, rings (26) re- the drive end bearings. CAUTION: Failure to remove these rings may result in damage to the double-row ball bearings during FIGURE 24 TIGHTENING LOCK NUTS WITH TORQUE WRENCH installation of the timing FIGURE 26 CHECKING DRIVE END CLEARANCE WITH FEELER GAGE 14 gears. s. Brush the gear end splines both shafts with assembly semble with and threads of lubricant. As- the idler gear (42) to the idler shaft the large diameter boss toward blower body. Use plastic or rawhide to start idler gear onto shaft. t. Place oil finger on idler shaft with con- cave side in toward u. the mallet Lubricate flexlock idler shaft. Chock gear. nut (44) and install on rotor with wood block to prevent its turning. Tighten lock nut to seat gear against bearing sleeve. Then back off v. lock nut enough to permit f reel y. Rotor timing procedure. oil flinger to turn On the helical gear blower, rotor timing (rotor to rotor clearance) is adjusted by a system in which drive rotor rotational is transferred motion FIGURE 28 ROTOR AND SPACER BLOCK POSITION FOR INDEXING GEARS (AS VIEWED FROM GEAR END) of the to the idler rotor rotor by means of two meshed helical gears, each splined to its respective rotor shaft. The shaft, concave side out toward gear (see Fig. 27). (3a) If gears are being reused, align the index marks made on the gears during tear- axial position of the idler gear is fixed as the gear face butts against the bearing down. Make sure that the wide land in sleeve and is held there by a lock nut. The axial position of the drive gear is slightly adjustable as the drive gear is clamped be- the drive gear spline is aligned with the missing tooth on the drive rotor shaft. Start drive gear on rotor shaft using tween plastic enough a conical spring washer spring) and a lock nut. Axial the drive gear, accomplished the lock nut against (Belleville movement of by tightening spring or rawhide faced mallet far to engage flexlock nut two turns by hand. (3b) If new gears are used, align rotors paral- pressure, changes the angular relationship between the two rotors thereby changing their timing. (1) In order to time the rotors, it is first necessary to start the gears on their rotor shafts in proper relationship to each other. (2) Place Belleville Spring (48) on the drive FIGURE 27 POSITIONING BELLEVILLE SPRING AND DRIVE GEAR BEFORE ASSEMBLING TO DRIVE ROTOR SHAFT FIGURE 29 STARTING DRIVE GEAR ONTO SHAFT WITH SOFT FACED MALLET 15 approximately 15” (l-1/2 w. while stationary. meshing it teeth) idler gear and rotor remain Push drive gear onto shaft with idler gear. Use mallet clearances should be checked gages (see Fig. 31). to move gear The two drive end snap rings porarily (5) removed (26) tem- on page 14 should 6A A cc c c D B D BCA AB aligned, check rotor-to-rotor clearance at arrows in Fig. 28. If clearance is greater (6) feeler D now be replaced. Drive gear onto shaft by turning flexlock nut. When the inner faces of gears are than .016” continue turning nut .016” is obtained. Rotors should with Qm onto shaft far enough to engage flexlock nut two turns by hand (see Fig. 29). (4) When correct rotor timing has been estabIished, the other interior rotor and air box ADB c until then B BA D c DD A AB turn freely. If tightening drive gear lock nut does not free rotors, the gears have been improperly meshed. Remove drive gear, fit ~ FIGURE 31 POSITIONS OF ROTORS FOR CHECKING INTERNAL CLEARANCE a new Belleville spring, and repeat gear indexing procedure (Item 3b above). (7) Before making torque idler [42 mkg]. (8) final timing gear lock (1) Clearance between tip of one rotor lobe and valley of other rotor (C-C and D-D) adjustments, nut to 300 ft-lb should When rotors turn freely, it is still neces- the rotor lobes at position Adjust be (2) Clearance between the rotor tips and the housing halves should be a minimum of .0040 in. [.102 mm]. It should be measured at several places along the length of each of the four rotor lobes. (3) Gear end rotor to end plate clearance is measured between the end of each rotor so that clear- of each the rotors to valley positions. A-A ance at A-A is equal to B-B within + .001 in. [.025 mm]. Clearance must be checked on both sides lobe near each end. with to each other. It should checked several places along the length of the rotor for each of the four lobe tip and B-B to check clearance. Adjust clearance by tightening flexlock nut on drive rotor shaft. One-sixth of a turn of the nut will change the clearance by .005 in. [.13 mm]. of .0040 in. [.102 is measured perpendicular sary to adjust rotor clearances to be equal on both sides. Refer to diagram in Fig. 30. Use feeler gages placed between be a minimum mm]. This lobe and the gear end plate. rotor The gear end clearance for each model is specified in the table on page 12. If the gear end clearance is not within limits, re- check the drive end clearance (refer back to Item q.), as gear end and drive end clearance CAUTION: rotor-to-air are interdependent. These rotor-to-rotor and box clearances are extremely critical. Even though the blower may turn freely by hand when cold; under operating conditions, the parts expand, and the rotors are subject to slight deflection. If the clearances are not sufficient, the rotors may contact each other or the housing with destructive results. -------- 3U -I-ltiul’lt If the POSITIONS OF ROTORS FOR CHECKING TIMING 16 clearances are too great, the blower may not develop the airflow that is required to pressure or perform its 99. semblies function. x. Insert 14 cap screws Check gear backlash four intervals as described in places at 90° the Teardown the specified further with assembly. limits, (5) through as- holes in cover and end plate. Torque all cap screws to 28 to 32 ft-lb Sequence (Section Ill, Item B., 1., g.). NOTE: If any of the four readings are not within (18) and lock washers (6) and two cap screw and lock washer hh. [3.9 to 4.4 mkg]. Assemble lock washer drive shaft with tangs of shaft (see Fig. 33). do not proceed (21 ) to drive end of outward toward end If a new set of gears does not solve the problem then consider returning the unit to DuroFlow for credit y. towards a remanufactured blower. After correct gear backlash has been established, remove the six cap screws and z. spacers used to tern porari Iy secure the gear end plate to the housing halves. Assemble gasket (31 ) to gear end cover(1). Assemble gasket and cover to gear end plate with 14 cap screws (4), 14 lock wash- aa. ers (6) and 2 cap screw and lock washer assemblies (5). Torque all cap screws to 28 to 32 ft-lb [3.9 to 4.4 mkg] (see Fig. 32). FIGURE 22 ASSEMBLING SPIDER WASHER AND LOCK NUT TO DRIVE SHAFT ii. Reassemble lock nut (22) to drive shaft with chamfer toward blower body. Tighten nut securely with hammer and punch Fig. 34). NOTE: formed if blower rebuilding is to be peron a regular basis, a special tool for the drive detailed tool lock (see rotor drawing is available lock nut is suggested. for the fabrication from DuroFlow A of this upon quest. if the special tool is used, lock nut to 300 ft-lb [42 mkg]. re- torque FIGURE 32 ASSEMBLING GEAR END COVER AND GASKET TO END PLATE Move back to d rive end of blower. bb. cc. Remove lock nut (22) from drive rotor tem- dd . porarily y. Remove 4 cap screws(18) ee. ff . holding drive end plate to upper and lower housing halves. Assemble gasket (31 ) to drive end cover (30). Assemble plate. gasket and cover to drive FIGURE 34 TIGHTENING DRIVE SHAFT LOCK NUT SECURELY WITH BLUNTED CHISEL AND BALL PEEN HAMMER end 17 Choose jj. the lock washer tang that best lock nut (22). Bend the tang into the lock nut to prevent lock nut from backing off (see Fig. 35). aligns with a slot in the kk. Install oil gage plug (43) in gear end cover. II. Install two oil breather mm. nn. caps (8) in gear end cover. Install the other eight pipe plugs. If the unit is not to be installed immediately cover the air inlet and outlet openings prevent the entry of foreign material. to SECTION EIGHT Spur Gear Blowers As mentioned utilized tooth spur gears (besides the in Section tooth timing in the current gears) from 1, the former gears rather design. the Item B., l.,g. helical drive gear and idler gear in some way so that they can be differentiated upon reassembly. This can be done with the center punch and hammer or with an etching model change to the tool. current model is the addition of a Belleville spring washer behind the drive rotor timing gear. Therefore, when overhauling a blower with a reusable set of spur gears and rotors, it is optional whether The reassembly procedure for a spur gear blower is identical to that for the helical gear blower except for the spur gears are reused or replaced with a set of helical gears and Belleville spring. If it is desired to reuse the spur the gear assembly type. timing with the spur gears is controlled and timing. With the spur gears, assemble the idler gear as in Section Vll, Item B., 2., s. Assemble the drive gear to the drive shaft aligning the gear idex marks which were made prior to removing the timing gears. Chock the rotors with a gears, some steps in the teardown and reassembly procedures will differ from those for the helical gear Rotor to mark the design than The only former and h.; it is also necessary blower by wood block and torque both flexlock nuts to 300 ft-lb [42 mkg]. Check rotor timing with feeler gages as in selective assembly (matching a particular rotor to a particular gear). Therefore, it is essential each gear be replaced on the shaft from which it was taken. After Section Vll, Item B., 2., v., (7). With spur gears the rotor timing is notadjustable. If the timing is not within limits, remove the spur gears and replace with a new checking the gear backlash and marking the ends of the gear teeth for proper indexing as in Section Ill, set of helical 18 gears and Belleville spring. SECTION NINE Operating Limitations DuroFlow 45 Series blowers are designed to be operated at 4000 RPM maximum and no more than 2:1 pressure ratio. The table below gives characteristic inlet airflow speeds and and horsepower pressures. requirements Attempting to blower at speeds and pressures above the rated maximum will cause premature bearing and seal wear and will void the warranty. CAUTION: Outlet temperatures for various operate the should not exceed 350”F. OPERATING CHARACTERISTICS (Data based on standard air at inlet (14.7 psi @ 60”F) SPEED (RPM) 2000 MODEL 4504 Psl HP 2 165 2.5 145 130 120 5 225 205 8 9.5 11.5 185 175 162 12 15 110 CFM 3 6.5 10 12.5 150 15 18 HP 280 260 3.5 8 240 230 215 203 12 15 18.5 23 430 400 6 12.5 380 CFM 335 315 295 HP CFM HP 4.5 390 5.5 9 14 17.5 370 351 11 16.5 20.5 287 270 255 22 27 337 325 513 485 460 6.5 600 14.5 22.5 565 8 16.5 28 540 530 26 32.5 39 48 308 26 31.5 260 4 5 235 8 10 215 200 8 12 340 320 295 10 16 12 185 14.5 17.5 285 265 19 23 365 350 19 23.5 28.5 445 435 250 28 349 35 415 33.5 41 515 495 775 735 11.5 23 900 13.5 26 39 48 57 70 5 2 395 6 525 8 650 5 360 12.5 480 16 615 8 10 330 19 23.5 450 435 24 29.5 575 555 19 29 36 27 420 35 540 385 43 510 705 10 870 12 315 290 15 4512 HP 2 15 4509 CFM 5 8 10 4506 CFM 4000 3500 3000 2500 2 5 540 480 8 16 445 23 8 10 420 28 12 400 34 15 650 610 20 30 580 560 37 44 520 54 19 9.5 700 34 42 680 660 42 50 855 820 800 780 52 630 61 755 12 1040 14 1205 16.5 820 775 745 25 37 45 980 935 30 44 1150 1100 34 51 720 54 905 880 54 64 1065 1040 62 74 680 66 845 78 1010 90 SECTION TEN Lubrication Recommendations The blower gears and bearings are splash lubricated. Oil level should be checked daily. Wait three minutes Proper oil level must be constantly maintained to prevent overheating and damage to internal parts. after shutdown to allow oil to drain down before reading level at sight glass. Top up if necessary After through months installation of the blower, add oil through the oil fill plug on top of the drive end plate. Fill only until oil reaches the level midway in the oil gage plug sight glass in the gear end cover. Approximate oil fill plug. Every 500 hours of operation (or 6 whichever occurs first) the oil should be changed. oil capacities Oil used in DuroFlow blowers must meet or exceed the requirements of SAE specifications SE and CC. The are given below. viscosity Vertical-30 oz. [0.9L] Horizontal-56 oz. [1.7L] used depends upon ambient and severity of application, the following tabie; AMBlENT AIR TEMPERATURE –65 F to 40 F –54 C to 40°F to 110°F 40C I 4C to 43 C I I l.Oto 1.7 P.R. 0 to 10 psig pressure 0 to 10 in. Hgvacuum PRESSURE 1.7t02.0 For applications DuroFlow. SAE 20 SAE 20W SAE 40 P.R. 10 to 15 psig pressure 10 to 15 in. Hgvacuum RATIO SAE IOW outside Oils of different these limits, consult brands or types should not be mixed. 10W4O or 15W40 multigrade ordinary operating conditions. 20 oil is recommended for all air temperature i.e., pressure ratio, as in SECTION ELEVEN Parts Lists, Sectional and Exploded Views A list of current part numbers is available upon written request from DuroFlow. replacement parts may be ordered by part number from the Parts List. dbdb Alternatively, @d @@b@@@ Sectional View DuroFlow 45 Series Blowers VARIABLE ITEM NO. 12 23 NAME OF PART Top Housing 1 PARTS LIST 4512 4509 4506 4504 135069 135729 135431 135720 135437 135720 141562 180928 180932 180931 180926 180930 24 Shaft Key Drive Rotor 180929 32 Idler Rotor 180933 39 40 Mounting 46 Gasket Bottom 180927 141534 141535 Housing 135070 135432 Plate 135405 135436 135438 135442 141541 135716 135717 135718 141539 21 Exploded View DuroFlow 45 Series Blowers (Consult Mounted Item No. 1 2 3 4 5 6 7’ 8* 9 10 11 12 13 14 15 16’ 17 18 19 20 21 22 23 24 * Name of Part Part Number Cover-GearEnd . . . . . . . . . . . . . . . . . 135075 Self TappingScrew . . . . . . . . . . . . . . . . 129309 NamePlate. . . . . . . . . . . . . . . . . . . . . ,,, 143606 Capscrew. . . . . . . . . . . . . . . . . . . . . . . . 134674 Capscrew&L.W.Assy. 132579 Lockwasher. . . . . . . . . . . . . . . . . . . 2917 EndPlate-GearEnd .(137430) 180672 BreatherFilter..........,...,,,. 140887 Roller Bearing......,,,,,,...,.. 138113 Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 161200 BearingSleeve, . . . . . . . . . . . . . . . . . 138100 HousingHalf-Top ., ,.. Variable SealRing . . . . . . . . . . . . . . . . . . . . . . . . 139986 BearingSpacer, . . . . . . . . . . . . . . . . . . 134662 Shim . . . . . . . . . . . . . ...135726-7-8and 159076-7 PipePlug(l”) . .(158285) 186545 Ball Bearing.........,,.,.,,,,,, 138116 Capscrew. . . . . . . . . . . . . . . . . . . . . . . . 134675 Oil Deflector.,,..............,,, 139466 BearingSpacer........,.....,.. 134671 Lockwasher. . . . . . . . . . . . . . . . . . . . 138257 Locknut . . . . . . . . . . . . . . . . . . . . . . . 128040 Key . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Rotor-Drive., .,, ,,, . . . . . . . . . . . . Variable Note - Quantity Item Per Blower No. 25 26 27 28 29.. 1 4 1 14 4 28 (1) 1 (2) 1 2 4 2 1 4 2 As Required (2)2 2 14 1 1 1 1 1 1 Part Number and/or quantity needed with old style 30 31 32 33‘ 34 35 36 37 38 39 40 41‘ 42 43 44 45* 46 47 48 1-143095. 22 for Truck Part Quantity Name of Part Number Per Blower Oil Seal . . . . . . . . . . . . . . . . . . . . . . . ... 134870 1 4 125606 SnapRing.....................,,, Flexlock Nut . . . . . . . . . . . . . . . . . . ,,, 124793 1 135766 1 ClampWasher, . . . . . . . . . . . . . . . . . .. Finger. . . . . . . . . . . . . . . . . . . . . . . See Below Cover-DriveEnd. . . . . . . . . . . . . . . . . 1 135074 135715 Gasket . . . . . . . . . . . . . . . . . . . . . . . . 2 Variable Rotor-idler, . . . . . . . . . . . . . . . . . . . . EndPlate-DriveEnd. .(137429) 180673 (1; 1 Dowel . . . . . . . . . . . . . . . . . . . . . . . . . 10 121880 119034 Ferrule . ., . ., . . . . . . . . . . . . . . . . . 4 4 119058 “O’’Ring. . . . . . . . . . . . . . . . . . . . . . . . . CapScrew . . . . . . . . . . . . . . . . . . . . . .,, 100963 4 Lockwasher. . . . . . . . . . . . . . . . . . . 4 2675 HousingHalf-Bottom . ... 1 Variable Mounting Plate(Vertical) 1 Variable PipePlug(318’’). .,, ,,, ,,, ,,, ,.. . 21360 (2) 2 or O Gearldler L,H. . . . . . . . . . . . . . . . . . . .,, 181377 1 Oil GagePlug. . . . . . . . . . . . . . . . . . . . . 137799 1 FlexlockNut . . . . . . . . . . . . . . . . . . 2 124793 PipePlug(112’’), ,,, ,,, ,,, ,, . . . . . (4) O or 2 9620 Gasket . . . . . . . . . . . . . . . . . . . . . . . . .,, Variable 2 GearDriveR.H.,,,....,......,,, 1 181378 Belleville Spring . . . . . . . . . . . . . . . . ,,, 181069 1 end plates are in parenthesis. ** Flingers - For V1/HL shaft configurations use 2-134652. For VB/HR shaft configurations use 1-134652 and DuroFlow Blowers) SECTION TWELVE Troubleshooting Guide— DuroFlow Positive Displacement Rotary Blowers Problem or Complaint Noisiness Probable Causes Rotor-to-Rotor Usual Reasons or Sources - Rotors Out of Time Contact - Excessive Pressure - Failed Bearing(s) Ratio - Failed Gears Failing Bearing(s) - Faulty Installation - Nonspec Oil - Contaminated Oil - Insufficient Oil - Oversized Belt Drive - Improperly Mounted - Overtightened - Misaligned Failing Direct Coupling - Insufficient Gears - Nonspec Sheave Belts Backlash Oil - Contaminated Oil - Insufficient Oil - Severe Torsional Failing Lubricated Coupling or Joint - Nonspec Grease - Contaminated - Insufficient Loose Attached Vibration Grease Grease - Belt Guard Hardware - Pump Mounting Bracket - Frame Members - In/Out Ducting - Improper Air Leakage Supports Relief Valve Setting - Blown Gaskets - Loose Ducting - Insufficient Belt Flutter Joints Static Tension - Long Span (Center-to-Center) Distance - Sheave Misalignment - Severe Torsional Poor Performance Restricted - Clogged Inlet Down Stream Filter Filtration - Undersized Inlet Pipe or Tubing Inlet Duct Length - Collapsed Inlet Hose Silo Vent Filter - Undersized - Excessive Air-to-Product Ratio Element Silo Vent Filter Outlet Outlet - Clogged Diffusion - Material Bridging - Insufficient 23 Unit - Excessive - Undersized Excessive Element - Undersized - Clogged Restriction Vibration Pipe or Tubing Ducting Length Pads (on Pneumatic Trailers) in Feed Hopper Feeder Speed - Material Caking at Inlet Nozzle - Material Caking at Inlet Nozzle or Funnel Erroneous Pressure - Loose Gauge Connection or Vacuum - Gauge Movement Indication Damaged - Gauge Miscalibrated - Gauge Tap Too Far from Unit Outlet - Improper Air Leakage Port Relief Valve Setting - Blown Gaskets - Loose Ducting Insufficient Rotor Speed Joints - Wrong Sheave Set - Wrong Motor Speed - Slipping Belts - Insufficient Engine Speed Excessive - Abrasive Rotor Clearances Wear of Rotor Surfaces - Rotors “Lag” Change in Conveyed Material - Material More Difficult - Material of Higher - Moisture Leaking Oil - Faulty Material to Fluidize Density Content - Foreign Failed Oil Seals Timed of Material Too High in Seal Bores Installation - Nonspec Oil - Contaminated Oil - Overheated Rotor Shafts End Cover Seams Not Tight Fuse Blowing or Circuit Excessive Bolts Loose - Gaskets Torn - Nonspec Oil - Oil Cavities Overfilled Oil Foaming Chronic - Through Motor Amperage - Excessive Pressure - Excessive Pump Speed - Line Voltage Droop - Air Density Increase Breaking Underrated Premature - Loose Electrical Connections - Foreign in Air Box Material Fuses - Unusually Heater Strip Actuation High Ambient - Underrated Overheat ing Ratio Excessive Pressure - Clogged Ratio Filter - Undersized - Undersized Temperature Heater Strips Element Filtration Unit Inlet Pipe or Tubing - Excessive Inlet Duct Length - Collapsed Inlet Hose - Clogged Silo Vent Filter Element - Undersized Silo Vent Filtration Element - Undersized - Excessive - Clogged Insufficient Rotor Speed Pipe or Tubing Ducting Diffusion Sheave Set - Wrong Motor Speed - Insufficient Length Pads (on Pneumatic - Wrong - Slipping 24 Outlet Outlet Belts Engine Speed Trailers) SECTION THIRTEEN WARRANTY GARDNER-DENVER INDUSTRIAL MACHINERY DUROFLOW BLOWERS 1800 GARDNER EXPRESSWAY QUINCY, IL 62305-4024 TEL: (217) 222-5400“ FAX (21 7) 223-5897 GENERAL PROWSIONS AND LIMITATIONS Industrial Machinery (the “Compan ‘) warrants to each original retail purchaser (“Purchaser of its new roducts from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, made with good material and workmanship. No warranty ismade with respect to: 1. An product which has been repaired or altered in sucK a way, in the Company’s judgment, as to affect the product adversely. 2. Any product which has, in the Company's judgment been subject to negligence, accidentt unproper storage, or improper installation or applicatlion. 3. Any product which has not been operated or maintained in accordance with normal practice and with the recommendations of the Company. 4. Components or accessories manufactured, warranted and serviced by others. Any reconditioned or prior owned product. Claims for items described in(4) above should be submitted directly to the manufacturer. placementof any product or art thereof which in the Company's judgment iS prove not to be as warranted. Labor shall be limited to the amount specified in the Company's labor rate schedule. Labor costs in excess of the Company rate schedule amounts or labor providedby unauthorized service personnel is not provide for by thISwarranty. AUcosts of transportation of roduct, labor or parts claimed not to be as warranted and, of repaired or replacement parts to or from such service facilities. shall be borne by the Purchaser.The Company may require the return of anypart claimed not to be as warranted to one of its facilities as designated by Company, transportation prepaid by Purchaser, to establish a claim under this warranty. Replacement parts provided under the terms of the warranty are warranted for the remainder of the Warranty Period of the product upon which installed to the same extent as if such parts were original components thereof. 5. WARRANTYPERIOD The Company’s obligation under this warrantyis limited to repairing or, at its option, replacin durin normal business hours at an authorized servicefacility of the Company, any DISCLAIMER THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE THE COMPANY MAKES NO OTHER WARRANTiES, EXPRESSED, IMPLIED OR STATUTORY, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY. THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE, EXCLUSIVE AND ONLY REMEDY Period AVAILABLE TO PURCHASER AND IN NO part which in its judgment proved not to within the applicable Warranty as follows: CASE SHALL THE COMPANY BE SUBJECT TO ANY BARE BLOWERS OTHER OBLIGATIONS OR LIABILITIES. UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE Basic bare blowers consisting of all parts within, are warLIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR ranted for 12 month from date of initial use or 18 months CONSEQUENTLAL DAMAGE, EXPENSES, LOSSES from date of shipment to the first purchaser, whichever OR DELAYS HOWSOEVER CAUSED. occurs first. Any disassembly or partial disassembly of the blower, or failure to return the "unopened"blower per Company instructions, will be cause for denial of warranty. OTHER COMPONENTS All other components are warranted for 12 months from date of initial use or 18 months from date of shipment to first purchaser, whichever comes first. LABOR TRANSPIRATION AND INSPECTION The Company will provide labor, by Company representative or authorized servicepersonnel, for repair or re- 25 No statement, representation, agreement, or understanding oral or written, made by any agent, distributor, representative, or employee o. the Corn any whtch is not contamed in this Warranty will be be g upon the Corn any unless made in writing and executed by an officer o the Company. This warrantyshall not be effective as to any claim which is not resented within 30 days after the date upon which the product is claimed not to have been as warranted. Any action for breach of this warranty must be commenced within one year after the date upon which the cause of action occurred. Any adjustment made pursuant to this warrantyshall not be construed as an admission by the Company that anyproduct was not as warranted. # COOPER Gardner-Denver Industrial Machinery For additional information, contact Gardner-Denver Industrial Machinery Division, 1800 Gardner Expressway, Quincy, Illinois 62305-4024 Telephone (217) 224-6600 FAX 217-224-7814 Telex 404332. Specificationssubject to change without notice, COPYRIGHT @ 1991 Cooper Industries, Inc. Litho in USA.