Gardener Denver D807 Installation and operating manual

Table of Contents Page
Torque Requirements ...……………….. 2
Oil Requirements ………………………. 2
Clearances ………….…………………… 2
Disassembly Procedures…………….… 3
Assembly Procedures .…………….…… 3
Parts List ……………………………….... 6
Tool List ………………………………….. 8
Safety ……………………………………. 11
WARRANTY
The seller warrants the goods sold hereunder against
defects in workmanship or materials under normal and
proper installation for a period of twelve (12) months from
the date of delivery. BUYER’S SOLE AND EXCLUSIVE
REMEDY UNDER THIS WARRANTY IS FOR THE
REPAIR OR REPLACEMENT AT SELLER’S OPTION,
WITHOUT CHARGE TO BUYER EXCEPT FOR SHIPPING
EXPENSES, AT THE OFFICE OF THE SELLER IN
LOUISVILLE, KY, OF ANY PART WHICH HAS PROVEN
TO BE DEFECTIVE AT THE TIME IT WAS DELIVERED.
ANY GOODS UNDER WARRANTY MUST BE
DELIVERED TO THE SELLER’S OFFICE FOR
INSPECTION BY THE SELLER AND, IF ANY SUCH
GOODS ARE FOUND TO BE DEFECTIVE, FOR REPAIR
OR REPLACEMENT. ALL FREIGHT AND EXPENSES
OF SHIPMENT TO AND FROM SELLER'S OFFICE
SHALL BE BORNE BY THE BUYER. THE SELLER IS
NOT RESPONSIBLE FOR ANY EXPENSES OF ANY
NATURE INCURRED FOR ANY REPAIRS TO
ALTERATIONS MADE BY OTHERS TO THE GOODS OR
ANY OTHER EQUIPMENT WITHOUT THE PREVIOUS
WRITTEN CONSENT OF THE SELLER. SHOULD THE
GOODS BE PARTIALLY OR FULLY INSTALLED,
ALTERED, STRIPPED, REPAIRED, SERVICED, OR
MAINTAINED BY ANY PERSON OTHER THAN
AUTHORIZED AGENTS AND EMPLOYEES OF THE
SELLER, WITHOUT THE PREVIOUS CONSENT OF THE
SELLER, OR MISUSED IN ANY WAY, THIS WARRANTY
SHALL BE VOID. THIS WARRANTY CONSTITUTES THE
ONLY WARRANTY BY THE SELLER OF THE GOODS
AND IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED
TO, WARRANTIES OF MERCHANTABILITY OR
WARRANTIES OF FITNESS FOR A PARTICULAR
PURPOSE. IN NO EVENT SHALL SELLER BE LIABLE
FOR BUYER’S ATTORNEY’S FEES.
NO CONSEQUENTIAL DAMAGES: UNDER NO
CIRCUMSTANCES SHALL THE SELLER BE LIABLE FOR
(A) ANY DAMAGE, INJURY, BREAKAGE OR LOSS OF
ANY KIND WHATSOEVER, (B) ANY LOSS OF INCOME,
OR (C) ANY CONSEQUENTIAL LOSS.
NO TORT LIABILITY: SELLER DISCLAIMS ANY
LIABILITY FOR CLAIMS BASED ON SELLER’S
NEGLIGENCE OR STRICT LIABILITY IN TORT.
PARTS: This warranty and all disclaimers and limitations of
liability shall apply to all parts sold to buyer.
TRAINING AND SUPERVISION: The buyer hereby
assumes the affirmative duty to properly educate, instruct
and supervise its employees and all others, except
employees of the Seller, in the safe, proper use and
operation of the goods. The Buyer agrees to indemnify the
Seller for any damages paid by the latter as a result of the
Buyer’s failure to perform this affirmative duty.
The goods are not designed or intended for use with every
substance. If the material which the buyer contemplates
transferring with the goods has corrosive or polymerizing or
other properties which may result in unsatisfactory or
dangerous operations, the Seller has no liability or
responsibility for performance of the goods.
RETURN OF GOODS: No goods supplied may be returned
to the Seller for credit without the Seller’s prior written
authorization before transportation thereof commences and
in such cases transportation must be prepaid and the
Buyer’s name, address, original order number and the
Seller’s invoice number must be clearly marked on the
shipping tag.
If any goods are returned to the Seller for repair or under
warranty and no instructions are received within two
months after Seller receives the goods for repair or sends
notice to Buyer of the disallowance of a warranty claim, the
Seller reserves the right to scrap the goods returned, and
no subsequent claim for any costs or losses will be
accepted.
APPLICABLE LAW AND VENUE: The rights and
obligations of the parties hereunder shall be governed in all
respects, including all questions of construction and
performance of this order, by the laws of Kentucky. All
disputes concerning this order shall be resolved in an
appropriate state or federal court located in Louisville,
Kentucky.
MODIFICATION OR RESCISSION: This warranty can only
be modified or rescinded by a written agreement signed by
an officer of both the Buyer and the Seller.
GARDNER DENVER, INC., Louisville, Kentucky (502)
266-6677

3
ASSEMBLY
11. Carefullyseparateendplatefromhousingandtapout
bearings (9), lip seals (12), labyrinth seals (51) and
retainers (219).
12. Clean all parts for inspection if there has been any
metaltometalcontact. Pleaseconsult yourdistributor
orfactoryforfullspecificationsheets. NOTE: Rotors,
sideplates, body, bearing, journals can be re-
manufactured. Inspect timing gears for wear and
pitting. Factory bearings and seals should be
installed.
13. It is important to try to determine cause of failure, i.e.,
over-speed,pressure,lackoflubrication,etc.,asitmay
necessitatechangesinoperationalprocedure,toensure
longer machine life.
1. Drainoilfrombothcoversbyremovingmagneticdrain
plugs.
2. Mark all parts with a center punch so that they can be
reassembled in same position (rotors, and plates,
housing and cover).
3. Remove key from shaft.
4. Remove oil slinger (20) and retainer plates (14) on
drive end sideplate.
5. Install a pair of gear plates p/n 530061204, to each
bearing bore. Alternately turn two 2-ton, 2-jaw pullers
(CG240)toremoveendplate(4)fromrotorhousing(3).
Tap out roller bearings (10), seals (12) and (51), seal
retainer (219).
6. Turnunitaroundandremoveboltsand washers (26 &
27) Tap non-drive end cover (7) with mallet to break
sealant and remove.
7. Removeboltsandwashers(29&25)using7/8"socket.
Replace bolts in end of rotor to protect threads when
using puller.
8. Position the blower with the driven gear on the right.
Align the timing gears for pulling by first matching the
timingmarksonthegears. SeeFig.1A. Turnthedrive
gear clockwise three teeth and mark a matching
reference line on each gear as shown in Fig. 1B. The
rotor lobes are now in their most open position. Using
a puller, CG240, the driven gear (left hand helix) may
nowberemovedwithoutjammingtherotors. Thisgear
isintwoparts--thegearrimandhub. Itisnotnecessary
to disassemble. Do not allow the gears to move from
the matched reference line while pulling. Use a light
rockingmotionwhilepullingthegeartoensurethatthe
lobes have not jammed.
Remove drive and non-drive gears. It is necessary to
remove keys from rotor shafts so that the gear plates
can be fitted for removing rotors from sideplates.
WARNING: Failuretoproperlypullthegearscould
result in damage to rotor keyways or a bent rotor
shaft.Rotorsmustbefreewhenpulling. Ifmachine
is locked up, pull both gears simultaneously.
WARNING: Discard gear retaining bolts after
disassembly. These bolts are installed with
permanent Loctite and may fail if reused.
9. Remove cap screws (61), washers (62), oil deflector
(15) and bearing lock plates (14).
10. Bolt gear plate p/n 530061204, with M6-70mm hex
head screws p/n 124006070, to side plate. Then use
puller, CG240, to press a rotor out of the sideplate.
Repeat process for other rotor.
DISASSEMBLY
Fig. 1A
Fig. 1B
TIMING MARKS ADVANCED 3 TEETH
(REFERENCE MARKS ALIGNED)
DRIVE GEAR DRIVEN GEAR
TIMING MARKS MATCHED
DRIVEN GEARDRIVE GEAR
Preparation of End Plates for Assembly
1. Make sure all parts are clean and free of any nicks or
burrs caused by disassembly.
See page 10 for seal pressing tools.
2. Press labyrinth seals (51), using tool p/n 530061202,
withstepfacingup,intobothendplates(4& 5). Press
retainer downward with cupped side down until firmly
seated on top of labyrinth seal.
3. Coat O.D. of lip seals (12) with Permatex #2 or
equivalent, and press into end plates, using tool p/n
530061203, with the lip facing upward until seated.
Lubricate lip seal with grease.

4
Gear End Assembly
4. Standrotorsinpresswith gearendsup. Itisadvisable
torestthe rotors on the lobeendsratherthanthe shaft
ends. Drive rotor should be on the left in a horizontal
position and the driven rotor vertical. Make sure
keyways are facing in the direction shown in Figure 2.
Lubricate shaft ends with oil so that seals are not
damaged on assembly.
5. Carefully install end plate (5) over shafts.
CAUTION: Makesurethetwo½"diameteroildrain
holes on the face of the end plate are positioned at
approximately four o-clock.
6. Lubricate shafts and install bearings (9) with bearing
numbers up. If no bearing number appears on either
side, look for a small acid mark (dot). This mark must
be up.
CAUTION: Thesebearingshavebeenflushground
on one side. Do not use standard bearings which
have not been flush ground within .001 tolerance.
(This modification is not reflected in the universal
bearing number, use factory approved parts.)
7. Install bearing retainer rings (14), with cutoffs facing
drain hole, and oil deflector plate (15) on driven plate
(right-handside). Securewithcapscrews(61)andflat
washers (62).
8. Checkclearancebetweenthefaceoftheendplateand
rotorlobes. Seeclearancechart. Ifclearancesarenot
within specifications, recheck parts to find cause of
improper clearance before proceeding.
9. Install gear keys (24) in rotor shaft keyways flush with
top of rotor shaft. Lubricate shafts.
10. Somemodelsarefittedwithsplitgearswhichincorporate
alocking tab that engages the gearalignment dowels.
Onthismodel,thelockingtabmustbeleftinplacewhile
removing or installing the gear hub. This will allow the
dowel pins to be retained to the outer gear shell.
Disassemblesplitgear. Install driven gear(right-hand
helix).
To install drive gear hub, align reference marks as
showninFigure1B. Carefullyinstallsplitgeartoavoid
mashing any teeth when engaging opposite gear.
11. Install washers (25) and secure with cap screws (29)
using a few drops of Loctite #242 (removable thread
locker) on each screw.
12. Removeassemblyfrompressandstandonworktable
with gears down. Place blocks under end plate to
preventassembly from falling over. Drive gear should
remain on left side.
13. Installhousing(3)overrotors,making suredowelpins
(22) are still in place and punch marks are lined up. It
is not necessary to use a sealant on either side of
housing. Secure temporarily with four evenly spaced
hex head cap screws M10 x 25mm p/n 128010425.
14. Checkendclearancewithdepthmicrometerwithaflat
bar or feeler gauges.
15. Wrap keyways with cellophane tape. Install drive end
plate,makingsuredowelpins(22)arestillinplaceand
the punch marks are in line.
CAUTION: Makesurethetwo½"diameteroildrain
holes on the face of the end plate are positioned at
approximately four o-clock.
Remove tape and install oil slinger on bottom shaft,
securing grub screws by using a few drops of Loctite
#242(removablethreadlocker)oneachscrew. Install
drive end cover (6) using silicone sealant and secure
with capscrews and washers ( 27 & 301).
Adjusting Rotor Interlobe Clearance
16. Thedrivengearismadeoftwopieces. Theoutergear
shell is fastened to the inner hub with four cap screws
and located with two dowel pins. Some models are
fitted split gears which incorporate a locking tab that
engagesthegearalignmentdowels. Onthismodelthe
locking tab must be left in place while removing or
installingtheoutergear shell. Thiswillallowthedowel
pinstoberetainedtotheoutergearshell. Alaminated
shim, made up of .003 laminations, separates the hub
andtheshell. Byremovingoraddingshimlaminations,
thegearshellismovedaxiallyrelativetotheinnerhub.
Being a helical gear, it rotates as it is moved in or out
and the driven rotor turns with it, thus changing the
clearance between rotor lobes. Changing the shim
thickness .014 will change the interlobe clearance
approximately .005.
Fig. 2
DRIVE DRIVEN
ASSEMBLY (Continued)

* Available through Gardner Denver, Inc.

WELD ALL AROUND

3 HOLES EQUISPACED
5 HOLES EQUISPACED
COMMON
HOLE

11
SAFETYSAFETY
SAFETYSAFETY
SAFETY
PRECAPRECA
PRECAPRECA
PRECAUTIONSUTIONS
UTIONSUTIONS
UTIONS
•Rotating shafts can be dangerous. You can snag clothes, skin, hair, hands, etc. This can cause serious injury or death.
• Do not work under the vehicle when the engine is running.
• Do not work on a shaft (with or without a guard) when the engine is running.
• Do not engage or disengage driven equipment by hand from under the vehicle when the engine is running.
• In order to avoid becoming entangled, install the power take off and/or shaft behind the frame rail, tanks, battery box, etc.
• If power take off and/or shaft are still exposed after installation, install a guard.
• Install a support strap when servicing a drive shaft to prevent personal injury.
• A serious or fatal injury can occur . . .
if you lack proper training
if you fail to follow proper procedures
if you do not use proper tools and safety equipment
if you assemble driveline components improperly
if you use incompatible driveline components
if you use worn-out or damaged driveline components
if you use driveline components in a non-approved application.
• This manual contains safety instructions. Read, understand and follow this manual.
Get proper training
Learn and follow safe operating procedures
Use proper tools and safety equipment
Use proper components in good condition
Note:
- Blower housing and associated piping or accessories may become hot enough to cause major skin burns on contact.
- Internal and external rotating parts of the blower and driving equipment can produce serious physical injuries.
Do not reach into any opening in the blower while it is operating.
- If blower is operated with piping disconnected, place a strong coarse screen over the inlet and avoid standing in the
discharge air stream.
- Stay clear of the blast from pressure relief valves and the suction area of vacuum relief valves.
- Avoid extended exposure in close proximity to machinery with high intensity noise levels. Wear adequate ear protection.
- Use proper care and good procedures in handling, lifting, installing, operating and maintaining the equipment.