Gardner Denver GD150 User manual

S er vice
Instru ction
Man ual
GD150
ROTARY VANE
COMPRESSOR
4990716000
November 25, 2014

Page 2
Contents
Chapter
Page
1 Health & Saf et y
Health & Safety Issues ....................................................................................................................................................... 3
2 G ener al
2.1 Identification..................................................................................................................4
2.2 Precautions........................................................................................4
2.3 Inspections ........................................................................................4
3 Blade R eplac emen t
3.1 Blade Removal ....................................................................................5
3.2 Blade Replacement ............................................................................6
4 Sideplate A ssemblies
4.1 Removing the Drive Coupling ..............................................................7
4.2 Cowl Removal .....................................................................................8
4.3 Fan Removal.......................................................................................8
4.4 Sideplate Removal ............................................................................9
4.5 Bearing and/or Seal Removal ............................................................10
4.6 Sideplate Re-assembly ....................................................................12
5 R ot or Assembly
5.1 Removing the Rotor Assembly ...........................................................15
5.2 Bearing Inners ...................................................................................15
5.3 Refitting the Rotor Assembly ................................................................16
6 Setting Clear ances
6.1 Free Movement Check .......................................................................17
6.2 Establishing Shim Pack Size ...............................................................17
6.3 Checking Side Plate Clearance ..........................................................18
6.4 Checking the ‘Float’ ............................................................................18
7 T echnical Data .....................................................................................19
8 R eplac emen t parts ...................................................................20 -21
Compressor parts...................................................................................22-23
W ar r an t y
One screw in each bearing housing cap and
Side plate is fitted with a lead plug. Removal of these will invalidate the
warranty if the machine is still within that period.

Page 3
1
Health & Safety
SERVICING.
READ THE WHOLE MANUAL BEFORE COMMENCING AN Y
ENSURE THE DRIVE TO THE MACHINE CANNOT BE ENGAGED
WHILST SERVICING IS IN PROGRESS
Static elec tr icit y .
Ensure, that where required, the compressor and ancillaries are earthed
In accordance with BS5958 Part 1 1983; ‘Control of Undesirable Static
Electricity’.
Powder-air combinations are potentially explosive.
Drive line .
It is the responsibility of the installer of the equipment to ensure that all
Rotating and moving parts of the installation are adequately guarded to
a standard which complies with the prevailing safety legislation.
C ompressor .
The compressor has internal moving parts, some of which may be accessed
Through the inlet and outlet apertures. Do not place any objects especially
fingers into these apertures since personal injury could result.
I nstallation.
A relief valve must be fitted in the outlet pipe work as close to the
compressor as possible. The valve must be positioned so as not to vent air
on to any personnel since the air discharged will be hot and can cause
severe burns.
S er vic e .
The compressor and other installed components may contain accumulated
dust. Appropriate respiratory protection is recommended in line with
normal safe working practices.
F ir e .
The compressor includes seals made of fluoroelastomer polymers which
degrade if exposed to temperatures above 300°C. If the material has been
so exposed then it must not be handled with bare hands.
Relief V alv e Check
This procedure should be carried out every month to clear the valve seat and
check the valve is functional. (Ear protection is recommended). Function of
the relief valve should always be checked after major servicing.
In
accordance with our policy of continuous product improvement, Gardner Denver
Drum reserve the right to alter details and specifications without notice.

Page 4
2
General
2.1
Iden tifica tion
The
body number of the machine is shown on the body number
label, attached to the machine.
Body numbers are also stamped along one of the compressor body
corners/ edges next to the ‘T’ (Tested) stamp.
The suction / delivery ports and the direction of rotation are clearly
marked to permit the orientation to be identified.
CAUTION
Oil, grease or dirt must not
be allowed to enter the
internals of the machine.
2.2 P r ecautions
The exterior of the machine and ancillaries should be
steam cleaned prior to removal from the vehicle and /or
before commencement of any dismantling.
All mating parts should be marked during dismantling
to ensure correct re-assembly.
2.3 I nspection (prior to servicing)
Excessive radial movement of the machine drive shaft
indicates bearing wear, with the result that the rotor may
have damaged the bore of the body or the faces of the
side plates. If this is the case, the machine should be
returned to the Gardner Denver Drum representatives
for examination and possible refurbishing.
See installation, operating & maintenance
instructions to check the blade wear status.

Page 5
3
NO TE
Blade R eplacement
If
blade replacement is necessary due to product ingress or blade
breakage, remove both side plates (described in section 4) and the rotor
assembly (as described in section 5) and thoroughly clean the body and
rotor.
Routine blade replacement can normally be under taken by removal of
the non-drive end sideplate assembly only (as described in section 4).
Failure to undertake a
complete cleaning operation
may result in premature failure
of the replacement blades.
3.1 Blade R emo val
See Sections:- 4.2,4.3 and 4.4
See Fig 6 for machine support positions.
Worn
blades are removed by sliding them outwards. The easiest
access to each blade/slot is obtained by positioning the blade at the
widest rotor to body gap (opposite the Nip). See fig 1.
NO TE
As the rotor is rotated to
access the lower slots,
support the weight of
the rotor to prevent
scoring of the body.
NO TE
Ensure that grease from dirty
hands is removed from all
blade surfaces with a cleaning
solvent prior to fitting.
NIP
Figure 1 .Blade R emo val

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3.2 Blade
R eplac emen t
When fitting the blades, ensure that the curved edge of the blade follows the
contour of the rotor. See fig 2.
The 6 blades should be replaced using the same method / caution as
used on blade removal.
When blade replacement is complete, refit the sideplate as described
in section 4.6
Figure 2. Blade Or ien ta tion

Page 7
4
Sideplate
If the drive end of the machine is to be removed / inspected, then the drive flange
/ coupling must be removed first. (See fig4). An isometric view of the
sideplate and cowl assembly can be seen in fig 3.
Key
1 Key
2 Grub Screw
3 Shoulder Screw
4 Drive Flange
5 Cowl (Drive End shown)
6 Mounting Bush
7 Cap Screw
8 Star Tolerance ring
9 Fan
10 Cap Screw M10x20
11 Bearing Housing Cap
12 Cap Screw M10x 25
13 Sideplate
CAUTION
Take care not to damage
the threads in the shaft
end.
Figure 3. Sideplate and Cowl A ssembly .
4.1 R emo ving the Drive C oupling
The drive flange is secured to the shaft by a key and a grub
screw. Loosen the grub screw using an Allen key then
remove the fan with a suitable extractor or simply tap the
drive flange with a soft/ copper hammer off the end of the
shaft in the direction shown. See fig 4.
Figure 4.
Drive Flange r emo val .

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4.2
Cowl R emo val and Mounting Feet R emo val
To
remove the drive end cowl follow 4.1, then loosen and remove the 4
socket cap screws in the corners of the cowl. The cowl and mounting
foot can now be removed.
For the non drive cowl, follow the above.
4.3 Fan
R emo val
C A UTION
The cooling fan is connected to the shaft by a star tolerance
ring.
Use a fan extractor as shown in fig 5, making sure that the
clamps are positioned in the arrowed portion of the fan.
Alternatively, use a mallet and A length of bar to force the
fan from the star tolerance ring by tapping on the central
boss. Discard the old star tolerance ring and replace.
The star tolerance ring must
not be re-used! A slipping
fan would result in
insufficient machine cooling.
NO TE
Protect the end of the Rotor
Shaft by using packing
against the fan extractor and
the shaft.
Figure 5. Fan removal using a fan
ex tr ac t or .

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4.4 Sideplate
R emo val
Support the machine approximately 45˚to the horizontal with the nip of
the machine closest to the bench surface. The nip is identified by a
stainless steel shouldered screw in the sideplate. Wooden supporting
block s can be used
for this purpose. Fig 6.
Key
1. 10mmStainlessSteel
Shoulder Screw
2. Supporting Blocks
(If used)
CAUTION
Only do this if the warranty
period has expired,
otherwise this will invalidate
any existing warranty
available.
Figure6.Supportingthemachineusingwooden blocks . (sideplatesremovedforclarity).
NO TE
It may be necessary to lightly
tap the side of the sideplate
with a soft faced hammer to
break the sideplate to body
‘O’ring seal.
1. Remove the lead seal which is in one of the sideplate
socket cap screws.
Fig. 7.
2. Carefully remove the 3 socket cap screws and shoulder
screw connecting the sideplate to the body. A slight drop
of the rotor will be felt.
3. Remove the sideplate and ‘O’ring checking that
the ‘O’ring is not damaged.See Fig 8.
Key
1. St/St Shoulder Screw
2. M10 Cap Screw (x3)
3. Lead Seal
Figure7
. Sideplate d is assembly .

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Page 10
Figure 8. Sideplate
r emo val .
NO FURTHER DISMANTLING IS NECESSARY FOR BLADE REPLACEMENT - SEE
SECTION 3.
4.5
B earing and/or Seal R emo val
Key
1. M10Cap Screw x 3
2. Bearing Housing Cap
3. Shim(s)
4. Oil Seal
5. Bearing
6. Oil Seal
7. Circlip
8. Air Seal
The sideplate assembly contains the parts shown in Fig 9.
The sideplate dismantling method at various
stages (as appropriate) is shown below.
Figure 9 , Seal/ B ear ing parts et c .
CAUTION
Only do this if the warranty
period has expired,
otherwise this will invalidate
any existing warranty
available.
1. Remove the lead seal from 1ofthe 3 socket cap screws in the bearing
housing cap.
2. Remove the 3 socket cap screws, then remove the bearing housing
cap & the shims.

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Page 11
The
sideplate and bearing housing cap are now sufficiently
exposed to easily remove items 3, 4, 5, 6, 7, and 8 in fig 9.
NO TE
Items 4, 6 and 8 must be
discarded and replaced
after removal.
3. Oil Seal ( I t em 4)
To remove the oil seal from the bearing housing cap, hold the cap
firmly in a vice and tap the oil seal out of the bore. Discard the oil
seal and replace.
4. B ear ing Outer (I t em 5)
Using fingers, pull the bearing out of the bore (see fig.10D- reversal
of). If the bearing is tight, tap the back face using a small diameter
bar.
5. Oi l Seal (Sideplate item 6)
Use a sharp bar to force the oil seal out of the bore. Discard and
replace the seal.
6. Circlip (i t em 7)
Use circlip pliers to remove. Reversal of fig. 10B.
7. Air seal (I t em 8) As item 5. Discard and replace the air seal.

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CAUTION
Do not interchange
sideplate assemblies
4.6 Sideplate R e -assembly
See Fig. 10 (A-D)
Degrease and examine each component for wear, burrs, damaged
threads etc. and rectify or replace as necessary. Clean all components
thoroughly before re-assembly.
With the bearing-housing cap removed, the re-assembly order of
the sideplate is as follows:
1. Air Seal (I t em 8)
Using a round dolly 0.5 mm smaller than the seal diameter, press the air
seal into position. (The air seal is positioned in the bore with the
recessed/stepped face facing upwards).
2. Circlip (I t em 7)
Insert the circlip and position it in the groove above the air seal.
3. Oil Seal (I t em 6)
Using a dolly 55Ø inside the recess, press the oil seal in to position (The
flat face of the seal sits on the bottom of the bore with the recessed face
uppermost).
4. B ear ing Outer (I t em 5)
Place the outer bearing into the bore ensuring that it is kept square (The
bearing is re-positioned into the bore with the ‘etched’ text facing
upwards). If it becomes jammed or is not seated properly, tap the top
of the bearing with a soft mallet until it seats in the correct position.
Bearing Housing Cap Re-assembly
1. Oil Seal (item 4)
Press the oil seal into the bore using a dolly. (The flat face of the seal sits
in the bottom of the bore with the recessed face upwards)
A
B C D
Air Seal Circlip Oil Seal B ear ing outer
Figure 10 a, b, c and d .

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CAUTION
Do not over tighten the
shoulder screw, as it
will strip the female
thread of the
aluminium body!
R e -assembling the rest of the Sidepla t e
With the compressor still at 45˚,
1. Place the ‘O’ring back into the sideplate groove and pass the
sideplate over the rotor shaft carefully engaging the bearing outer
onto the inner race. See Fig 11.
2. Carefully push the sideplate home against the body checking that the
‘O’ring is still correctly seated in the sideplate groove.
3. Loosely fasten the sideplate to the body using the 3 socket cap
screws and shoulder screw. Then tighten the socket cap s and
shoulder screw until lightly nipped.
4. Tighten the 3 socket cap screws to the appropriate torque setting
then tighten the shouldered screw . 25- 30 YeNm.
Key
1. Outer Bearing Race
2. Sideplate Assembly
3. O Ring
4. Inner Bearing Race
Figure 11. R eplacing the sidepla t e .
CAUTION
Ensure that the sideplate
face and air seal are free
from grease.
5. Fit the Bearing-housing cap using the 3 socket cap screws
leaving a 1- 2 mm gap between the face of the sideplate and
the bearing housing cap. See fig 12.
1-2m m
Key
1. M10Cap Screw x 3
2. Bearing housing cap
3. Shim(s)
Figure 12 .
R eplacing the bearing housing

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See section 6 for the clearance setting
procedure before proceeding further .
6. Once the
shimming is complete remove the bearing housing cap,
pack with grease and refit.
7. Place anew star tolerance ring onto the shaft and lightly coat the
diameter with copper slip to aid future separation.
8. Place the fan onto the shaft & press the fan over the star tolerance ring
until it is fully located using a tubular dolly. See fig 13.
9. Repeat, for the opposite end (if required).
NO TE
Make sure that the fans rotate
360˚ and are not catching on
any other part of the
machine.
Figure 13. Fitting the fan(s )using a dolly
.
10.Refit the
cowls, mounting feet and drive flange / coupling.(reversal of
section 4.2)

Page 15
5
Rotor Assembly
5.1
R emo ving the R ot or Assembly
Before this is
attempted it is necessary to remove both sideplates
(section 4) and the blades (section 3).
1. Protect the body bore from damage by inserting a thin sheet of
plastic or card between the body bore and the rotor. Item 1, Fig 14.
2. Withdraw the rotor partially outwards and then support the rotor
weight. Continue withdrawing the rotor placing upwards
pressure on the shaft end to prevent scoring the body. See Fig
14.
Key
1. Protective sheet
1
Figure 14.
R emo ving the R ot or A ssembly .
5.2
B earing I nners
Extracting the bearing I nner
1. To extract the bearing inner, you must carefully grind the diameter
of the bearing inner to generate a groove.
2. Gently tap the bearing inner with a hammer and a small bar approx.
5 mm in diameter to loosen it from the diameter. A noise should
be heard when the inner comes free from the rotor diameter.
See fig 15, for full illustration of removal details.
Figure 16 . B ear ing inner location using a hollow dolly .
CAUTION
Do not use a blow torch or
local temperatures may
damage the bearing.
R eplacing the B ear ing I nner
1. Ensure all the mating faces are clean and free from burrs / damage.
2. Heat the bearing inner to 120˚C, (248˚F) using an oven.
3. Quickly place the bearing inner over the rotor shaft & slide down to
the rotor face. To locate the bearing inner properly use a hollow
dolly. See Fig 16.
Fitting the bearing inner without heating could result in damage to the
shaft.

R ot or A
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Page 16
Figure 15. Extracting the bearing inner
5.3 R efitting the R ot or A ssembly .
Thoroughly clean the rotor and body bore.
This is a reverse of the removal (Section 5, step 1).
Ensure the body bore is protected by plastic or card
sheet.

Page 17
6
Setting Clearances
This
section requires a Dial Test Indicator (DTI) secured to one end of the
See Fig 17.
Figure 17. Dial T est indicator setup
6.1 Free Movement Check
1.
Ensure both bearing housing caps are free of the sideplates,
(screw loose) and pull/push the rotor to one end of its free travel.
2. Zero the DTI on the end of the shaft.
3. Push the rotor to the opposite end and record the DTI reading
This
measurement will be in the range of.625- .710mm.
NO TE
ALLCLEARANCESTO BECHECKED
WHENTHEMACHINEISCOLD& BEFO
RE GREASING!
6.2 Establishing Shim Pack Size
1. Push/pull the rotor towards the end to be checked, ensuring the
same axial position achieved in section 6.1.
2. Zero the DTI on the end of the shaft.
3. Slowly tighten the bearing housing cap retention screws, each a
little at a time. Once the bearing housing cap is tightened, record the
DTI reading. Subtract 150-200 microns from the DTI reading to give
the required shim pack size.
4. It is common for the sideplate clearance to be kept to a
minimum of between 150-160 microns.
Use a minimum of1anda maximum of3 shims per bearinghousingcap. (If
possible)
5. Loosen the bearing housing cap screws & leave a
clearance of approximately1-2mm.
Repeat steps 1-5 for the opposite end of the machine.

Page 18
6.3 Checking Sideplate Clear anc e
1.
Remove the bearing housing caps, fit the shim packs and then
refit the bearing housing caps leaving a clearance of 1-2mm
between the caps and the sideplates.
2 Repeat the exercise of tightening each bearing housing cap,
and recording the DTI reading. Repeat for the opposite end
of the compressor keeping the first end tightened.
6.4 Checking the
‘F loa t ’
NO TE
To increase the clearance
shims are removed and to
decrease clearance shims
are added.
With the sideplate clearances set, a final check of the
machine is to check the ‘float’.
1. Push the rotor toone end.
2. Zero the DTI on the end of the shaft.
3. Push the rotor to the opposite end and record the
reading.
This reading should equal Free Movement Check
(Section 6.1) minus both fixed clearance
measurements (Section 6.3)
NO TE
After clearance setting, turn
the rotor to check that the
blades fall freely from the
rotor slots. 6 blades will
drop on a 360˚turn.