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Summary of Contents for Gardner Denver Industrial Series
- Page 1 PARTS LIST OPERATING AND SERVICE MANUAL HELIFLOW INDUSTRIAL SERIES BLOWERS 5” GEAR DIAMETER Models HYEL_AA HYEL_AB HF-7-602 Version: 06 January 6, 2017...
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Page 2: Maintain Blower Reliability And Performance
When ordering parts, specify Blower MODEL and SERIAL NUMBER (see nameplate on unit). Rely upon the knowledge and experience of you AUTHORIZED DISTRIBUTOR and let them assist you in making the proper parts selection for your blower. To Contact Gardner Denver or locate your local distributor: Visit: www.contactgd.com/blowers call: (800)372-2222... -
Page 3: Foreword
FOREWORD â Gardner Denver blowers are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. -
Page 4: Safety Precautions
SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel. -
Page 5: Table Of Contents
Section 1, Equipment Check ........................9 Section 2, Installation..........................11 Section 3, Maintenance ......................... 17 Gardner Denver Lubricant Order Information ..................18 Section 4, Operation ..........................21 Section 5, Special Tools Required ......................24 Section 6, Disassembly Instructions ....................... 31 Section 7, Assembly Instructions, Air Seals (Standard) ................ - Page 6 INDEX Air Filters And Filter Silencers ......20 Maintenance, Section 3 ........17 Assembly Instructions, Air Seals (Standard) Matrix/Menu ............. 7 Section 7.............33 Mounting Configurations ........ 11 Assembly Instructions, Mechanical Seals Operation, Section 4 ........21 Section 9.............45 Parts List, Section 10 ........54 Blower Startup Checklist .........22 Parts List, Section 8 ........
- Page 7 LIST OF ILLUSTRATION Figure 2-1 – Vertical Blower Mounting Configurations And Outline ............12 Figure 2-2 – 514 Blower Mounting Configurations And Outline ............... 13 Figure 2-3 – Belt Drive Overhung Load Calculations ................15 Figure 3-1 - Lubrication .......................... 17 Figure 3-2 –...
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Page 8: Matrix/Menu
GARDNER DENVER HELIFLOW INDUSTRIAL SERIES BLOWERS MATRIX/MENU NOTICE TO CUSTOMER – To find the construction options for Your blower unit, FILL IN THE BALANCE OF LETTERS OR ___ ___ ___ ___ ___ ___ ___ NUMBERS FROM YOUR UNIT NAMEPLATE COLUMN NUMBER... -
Page 9: Introduction Your Key To Trouble Free Service
There is no guesswork in the manufacture of your highly advanced Gardner Denver blower and there must be none in preparing the blower to get the job done in the field. -
Page 10: Section 1, Equipment Check
STORAGE Your Gardner Denver Blower was packaged at the factory with adequate protection to permit normal storage for up to six (6) months. If the unit is to be stored under adverse conditions or for extended periods of time, the following additional measures should be taken to prevent damage. - Page 11 REMOVING PROTECTIVE MATERIALS The shaft extension is protected with rust inhibitor which can be removed with any standard solvent. Follow the safety directions of the solvent manufacturer. Blower inlet and outlet are temporarily capped to keep out dirt and other contaminants during shipment. These covers must be removed before start-up.
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Page 12: Section 2, Installation
SECTION 2 INSTALLATION LOCATION If possible, install the blower in a well lit, clean, dry place with plenty of room for inspection and maintenance. FOUNDATIONS For permanent installations we recommend concrete foundations be provided, and the equipment should be grouted to the concrete. It is necessary that a suitable base be used, such as a steel combination base under blower and motor, or a separate sole plate under each. -
Page 13: Figure 2-1 - Vertical Blower Mounting Configurations And Outline
303HYE800-A (Ref. Drawing) FIGURE 2-1 – VERTICAL BLOWER MOUNTING CONFIGURATIONS AND OUTLINE... -
Page 14: Figure 2-2 - 514 Blower Mounting Configurations And Outline
302HYE800-C (Ref. Drawing) FIGURE 2-2 – 514 BLOWER MOUNTING CONFIGURATIONS AND OUTLINE... - Page 15 NOTICE When changing mounting configuration, it will be necessary to reposition oil level gauge (H), and drain plug (A). Refer to , page 17, for correct location. FIGURE 3-1 For Vertical Models, the oil slinger must be on the lower rotor or blower failure is immediate. DRIVE INSTALLATION When selecting a V-belt drive, check to be sure the shaft overhung load limitation is not exceeded.
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Page 16: Figure 2-3 - Belt Drive Overhung Load Calculations
Maximum Gear Dimensions Allowable Diameter (Inches) Moment (Inches) (LB-IN) (Max) 3.12 0.25 8100 MAXIMUM ALLOWABLE MOMENT DRIVE SHAFT ILLUSTRATION 0.000 1.000 0.250 0.966 0.500 0.926 0.750 0.879 1.000 0.823 1.250 0.751 0.025 0.997 0.275 0.962 0.525 0.922 0.775 0.874 1.025 0.816 1.275 0.742... - Page 17 All system piping must be cleaned internally before connecting to the blower. Gardner Denver blowers are shipped dry from the factory. Do not attempt to operate the blower before following proper lubrication instructions. Permanent damage to the gears, bearings and seals will occur.
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Page 18: Section 3, Maintenance
SECTION 3 MAINTENANCE FIGURE 3-1 - LUBRICATION A. Oil Drain Plug B. Plug/Oil Fill H. Oil Level Sight Gauge GENERAL Blower efficiency and life depend on the quality of maintenance the blower receives. Maintenance must be done regularly and with care. Clean work space, tools, solvents and wiping rags are necessary to avoid transferring dirt into the unit. -
Page 19: Gardner Denver Lubricant Order Information
1 Quart 28G46 Case/ 12 Quarts 28G47 1 Gallon 28G42 5 Gallon Pail 28G44 55 Gallon Drum 28G45 Call your local Gardner Denver distributor to place your order for Gardner Denver Lubricants. Your Authorized Gardner Denver Distributor is: HF-7-602 Page 18... -
Page 20: Figure 3-3 - Synthetic Lubricant Chart
AEON PD Series Lubricant is formulated especially for positive displacement blower service to provide maximum blower protection at any temperature. One fill of AEON PD Series Lubricant will last a minimum of 4 times longer than a premium mineral oil. Refer to FIGURE 3-3, page 19. * For ambient temperatures less than 10 F, but not less than -20 F, the use of oil sump heaters or... - Page 21 AIR FILTERS AND FILTER SILENCERS Servicing the air filters is one of the most important maintenance operations to be performed to insure long blower life. Servicing frequency of filter elements is not time predictable. A differential pressure indicator, with a continuous gauge reading, should be installed across the inlet filter.
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Page 22: Section 4, Operation
SECTION 4 OPERATION Future operating problems can be avoided if proper precautions are observed when the equipment is first put into service. NOTICE Machines are shipped without oil in the sumps. Do not operate before adding lubricant. Before starting under power, the blower should be turned over by hand to make certain there is no binding, or internal contact. - Page 23 “Jog” the unit with the motor a few times to check that rotation is in the proper direction, and to be certain it turns freely and smoothly. The internal surfaces of all Gardner Denver units are mist sprayed with a rust preventive to protect the machine during the shipping and installation period. This film should be removed upon initial startup.
- Page 24 SAFETY PRECAUTIONS 1. Do not operate blower with open inlet or outlet port. 2. Do not exceed specified vacuum or pressure limitations. 3. Do not operate above or below recommended blower speed range. 4. Blower is not to be used where non-sparking equipment is specified. 5.
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Page 25: Section 5, Special Tools Required
SECTION 5 SPECIAL TOOLS Figure 5-1 – BEARING DRIVER (EQ144211-1) Figure 5-2 – LOCKNUT SOCKET (EQ144211-2) HF-7-602 Page 24... -
Page 26: Figure 5-3 - Carrier & Slinger Driver (Eq144211-3)
Figure 5-3 – CARRIER & SLINGER DRIVER (EQ144211-3) Figure 5-4 – INSERT DRIVER (EQ144211-4) HF-7-602 Page 25... -
Page 27: Figure 5-5 - False Bearing (Eq144211-5)
Figure 5-5 – FALSE BEARING (EQ144211-5) HF-7-602 Page 26... -
Page 28: Figure 5-6 - Slinger / Bearing Housing Puller (Eq144211-6)
Figure 5-6 – SLINGER / BEARING HOUSING PULLER (EQ144211-6) Figure 5-7 – SEAL INSTALLATION SLEEVE (EQ144021-7) HF-7-602 Page 27... -
Page 29: Figure 5-8 - Hand Crank (Eq144211-8)
Figure 5-8 – HAND CRANK (EQ144211-8) HF-7-602 Page 28... -
Page 30: Figure 5-9 - Mechanical Seal Driver (Eq144211-9)
Figure 5-9 - MECHANICAL SEAL DRIVER (EQ144211-9) HF-7-602 Page 29... -
Page 31: Figure 5-10 - False Bearing Spacer (Eq144211-10)
Figure 5-10 – FALSE BEARING SPACER (EQ144211-10) HF-7-602 Page 30... -
Page 32: Section 6, Disassembly Instructions
SECTION 6 DISASSEMBLY INSTRUCTIONS Required tooling: · Trunnion should be used during disassembly. If a trunnion is not available, an overhead hoist and heavy duty work table can be used. Work table should be capable of holding 700+ lbs. · Gear puller ·... -
Page 33: Figure 6-1 - Bearing Housing Removal
16. Remove socket head bolts (29) that attach the gear-end bearing housing (3) to air cylinder (1). 17. Using bearing housing puller EQ144211-6, remove gear-end bearing housing. Install fixture and place hydraulic cylinder between rotor shaft and fixture as shown in FIGURE 6-1. Apply pressure back and forth between both rotor shafts evenly until bearing housing is free. -
Page 34: Section 7, Assembly Instructions, Air Seals (Standard)
SECTION 7 ASSEMBLY INSTRUCTIONS - HYEL_AA Required tooling: · Trunnion and mounting plate - If a trunnion is not available, an overhead hoist and heavy duty work table can be used. Work table should be capable of holding 700+ lbs. ·... -
Page 35: Figure 7-3 - Loctite 620 Applied To Bearing Housing
5. Repeat steps 1 through 4 for remaining piston ring carriers, also for idler (short) rotor. 6. Install piston rings (10) into the piston ring carrier on gear-end and drive-end of both rotors, one at a time, starting with ring closest to rotor body. Ensure ring ends are hooked together properly. Position ring end gaps 180°... -
Page 36: Figure 7-5 - Retaining Ring Installation
Figure 7-5 – RETAINING RING INSTALLATION 9. Repeat steps 7 and 8 for remaining insert and retaining ring. 10. Repeat steps 7 through 9 for gear-end bearing housing (3). 11. Attach mounting bracket to inlet port of air cylinder (1) and mount air cylinder on trunnion. 12. -
Page 37: Figure 7-6 - Rotor Installation
Figure 7-6 – ROTOR INSTALLATION 20. Using a depth micrometer, measure and record total rotor to bearing housing end clearance for each rotor. This is accomplished by measuring distance from top edge of air cylinder to top of rotor lobe while rotors are in vertical position. -
Page 38: Figure 7-8 - False Bearing Installation
26. Thread 3/4" pull rod into end of idler rotor shaft. Place slinger driver EQ144211-3 over pull rod. Place portable hydraulic cylinder over pull rod and onto driver tool. Install 3/4" flat washer and nut onto pull rod and draw slinger onto ring carrier. -
Page 39: Figure 7-10 - Bearing Retainer Plate Installation
Note: Maximum load applied to threaded rod must NEVER EXCEED 5 TONS. 35. Repeat step 34 to install bearing on gear-end of drive rotor shaft. 36. Verify gear-end axial clearance for both rotors. With gear-end up, rotate rotors so a feeler gauge can be inserted between end of the rotor lobe and the inner surface of the bearing housing. -
Page 40: Figure 7-11 - Pinion Gear Installation
43. Install key (36) into keyway on idler rotor shaft. 44. Thread pull rod into end of the idler rotor shaft. Heat pinion gear to 350° F. 46. Place heated gear onto idler rotor shaft (over pull rod) and align keyway with key in shaft. Place driver tool EQ144211-1 over pull rod. -
Page 41: Figure 7-12 - Shrink Disk/Timing Gear Installation
52. Install shrink disk/timing gear assembly onto rotor shaft and align teeth so timing gear and pinion gear mesh. Firmly push against bearing inner race. Finger tighten the 12 locking bolts ensuring the gear can still be rotated on shaft. Reference FIGURE 7-12. Figure 7-12 –... -
Page 42: Figure 7-13 - Install Drive And Cover Over Shaft
57. Measure backlash of the gears using a dial indicator with a magnetic base. Gear backlash is distance (in the circumferential direction) a gear tooth can freely move when the mating gear is fixed and should be measured in three places (every 1/3 turn). Lock idler rotor from turning by wedging a feeler gauge or shop rag between tip of a lobe and air cylinder. - Page 43 67. Apply Loctite 515 gasket eliminator to the flange of sump cover prior to installation. 68. Attach sump cover to gear end bearing housing using four socket head cap screws (31) in two center holes on each long side of cover. Install remaining screws (27). Tighten all screws. Torque: 37 ft-lbs 69.
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Page 44: Section 8, Parts List
SECTION 8 PARTS LIST - HYEL_AA 300HYE810-D (Ref. Drawing) HF-7-602 Page 43... - Page 45 Order by Part Number and Description. Reference Numbers are for your convenience only. MODEL Ref. HYEL_AA Description Req. CYLINDER ............... 300HYE002 ROTOR GROUP .............. CLOCKWISE DRIVE ROTATION ......... 302HYE4028 COUNTER CLOCKWISE DRIVE ROTATION ....303HYE4028 HOUSING-BEARING GEAR ..........301HYE006 HOUSING-BEARING DRIVE ........... 300HYE006 COVER-GEAR ..............
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Page 46: Section 9, Assembly Instructions, Mechanical Seals
SECTION 9 ASSEMBLY INSTRUCTIONS - HYEL_AB Required tooling: · Trunnion and mounting plate - If a trunnion is not available, an overhead hoist and heavy duty work table can be used. Work table should be capable of holding 700+ lbs. ·... -
Page 47: Figure 9-3 - Mechanical Seal Installation
6. Install mechanical seals. 6a. Place drive-end bearing housing (4) in a horizontal position in a hydraulic press with air side surface facing down. 6b. Place spring loaded carbon half of mechanical seal assembly (43) in one of the bearing housing bores with the carbon facing up. -
Page 48: Figure 9-4 - Rotor Installation (Mech. Seal)
Figure 9-4 – ROTOR INSTALLATION (MECH. SEAL) 17. Using a depth micrometer, measure and record total rotor to bearing housing end clearance for each rotor. This is accomplished by measuring distance from top edge of air cylinder to top of rotor lobe while rotors are in vertical position. -
Page 49: Figure 9-6 - False Bearing Installation
Figure 9-6 – FALSE BEARING INSTALLATION 24. Thread 3/4" eye bolt into end of idler rotor and lift rotor until ends of rotor lobes contact bearing housing. 25. Using a depth micrometer, measure and record distance from top surface of outer ring of false bearing to top surface of inner ring. -
Page 50: Figure 9-8 - Retainer Plate Installation
31. Verify gear-end axial clearance for both rotors. With gear-end up, rotate rotors so a feeler gauge can be inserted between end of the rotor lobe and the inner surface of the bearing housing. Clearance should be measured and recorded for all three lobes on both rotors. Gear-end clearance: 0.005"... -
Page 51: Figure 9-9 - Pinion Gear Installation
41. Place heated gear onto idler rotor shaft (over pull rod) and align keyway with key in shaft. Place driver tool EQ144211-1 over pull rod. Place portable hydraulic ylinder over pull rod and onto driver tool. Install 3/4" flat washer and nut onto pull rod and tighten against hydraulic cylinder. Press gear onto rotor shaft until tight against bearing inner race. -
Page 52: Figure 9-10 - Shrink Disk/Timing Gear Installation
Figure 9-10 – SHRINK DISK/TIMING GEAR INSTALLATION 48. Verify total interlobe clearance. Through discharge port, insert feeler gauges between rotor lobes. Measurement is taken at pitch diameter of rotor lobes, just above widest cross sectional width of rotor lobe. Clearance is measured along entire length of meshing lobes for all three interlobe meshes. -
Page 53: Figure 9-11 - Drive-End Sump Cover Installation
52. Measure backlash of the gears using a dial indicator with a magnetic base. Gear backlash is distance (in the circumferential direction) a gear tooth can freely move when the mating gear is fixed and should be measured in three places (every 1/3 turn). Lock idler rotor from turning by wedging a feeler gauge or shop rag between tip of a lobe and air cylinder. - Page 54 61. Remove protective sleeve from drive shaft. 62. Attach sump cover to gear end bearing housing using four socket head cap screws (31) in two center holes on each long side of cover. Install remaining screws (27). Tighten all screws. Torque: 37 ft-lbs 63.
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Page 55: Section 10, Parts List
SECTION 10 PARTS LIST - HYEL_AB 301HYE810-B (Ref. Drawing) HF-7-602 Page 54... - Page 56 Order by Part Number and Description. Reference Numbers are for your convenience only. MODEL Ref. HYEL_AB Description Req. CYLINDER............... 300HYE002 ROTOR GROUP .............. CLOCKWISE DRIVE ROTATION ......... 302HYE4028 COUNTER CLOCKWISE DRIVE ROTATION ....303HYE4028 HOUSING-BEARING GEAR ..........303HYE006 HOUSING-BEARING DRIVE .......... 302HYE006 COVER-GEAR ..............
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Page 57: Warranty
GENERAL PROVISIONS AND LIMITATIONS Gardner Denver, Inc. (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its products 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 is made with respect to: 1. - Page 60 For additional information, contact your local representative or visit: www.contactgd.com/blowers ©2017 Gardner Denver, Inc. Printed in U.S.A.
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