Gardner Denver DRUM D9000 User manual

D9000
HOOK & CLAW
COMPRESSOR
Installation,
Operating &
Maintenance
Manual
(Original Instructions)
4991460001
September 2013

QUA Doc 1023
Issue 1
26/01/2010

1 Health & Safety
Health & Safety Issues ....................................2
2 General Description 3
2.1 Lifting and handling........................................4
2.2 Physical Data...................................................4
2.3 Orientation ......................................................5
3 Installation
3.1 Power requirements.......................................6
3.2 Mounting ........................................................6
3.3 Alignment .......................................................7
3.4 Belt Drive ...................................................7/10
3.6 Ancillary Equipment ................................10/11
4 Operating Instructions
4.1 Safety ............................................................11
4.2 Starting the compressor ..............................11
5 Maintenance Instructions
5.1 Routine Maintenance....................................12
5.2 Draining the Gearcase Oil ............................12
5.3 Refilling and checking the oil level ..............13
5.4 Relief Valve ...................................................13
5.5 Changing the Air Filter .................................14
5.6 Greasing the Drive Shaft Bearing Caps .......14
Contents
Chapter Page

Page 2
Publication 4991460001 (May 2000)
1. HEALTH AND SAFETY
Read this manual carefully before starting an Installation
Static electricity - Care should be taken to ensure, where necessary, that this and
any other equipment is earthed in accordance with BS 5958 Part 1 1983 "Control of
Undesirable static Electricity". (or other prevailing legislation in the country of opera-
tion). Powder / Air combinations are potentially explosive if not correctly earthed.
Drive line guards - Although care has been taken to avoid exposed rotating
parts, It is the responsibility of the installer of the equipment to guard the
exposed drive line in accordance with any prevailing safety legislation.
Never place your fingers into exposed inlet or outlet ports . If the rotors are
turned, even by hand, serious injury could result.
A relief valve must be fitted in the outlet pipework to protect the compressor which
must vent away from the operator. A notice, warning of the danger of burns from
vented air must be fitted near the relief valve. The relief valve is NOT intended to
protect the tank from over pressurisation (this is the responsibility of the tank
manufacturer
IN CASE OF FIRE
=
300OC +
+
THIS PRODUCT CONTAINS
FLUOROELASTOMER POLYMERS (VITON)
HYDROGEN
FLUORIDE
IMPORTANT: Fluoroelastomer Polymer seals
that have been exposed to temperatures of 300OC
and above MUST not be handled with bare hands
even when the seals have cooled down.

Page 3
Publication 4991460001 (May 2000)
Fig 1
A TYPICAL INSTALLATION
2. GENERAL DESCRIPTION
The D9000 compressor is an oil free hook and claw type compressor housed in an acous-
tic enclosure incorporating ancillary equipment. The unit is designed for the discharge of a
wide range of bulk powders and granules.(A D9000 fitted with an after-cooler is available
for the discharge of more heat sensitive products).
The D9000 is supplied in either Left Hand or Right Hand configuration to suit space
availability on the vehicle to which the unit is to be fitted (refer to Fig 3A).
A Belt Drive can be fitted to allow the D9000 to be driven from a PTO (Power Take Off)
rotating in either direction. On applications where drive from a PTO is not available, Drum
can supply hydraulic and electric drives or a remote diesel engine (for trailer or static
applications) Consult your Drum agent for appropriate drives.
Fig 1 shows a typical D9000 system package which features as standard:
• GRP acoustic enclosure and mounting bracket.
• Integral inlet filter.
• Integral Inlet and Outlet silencers.
• Relief Valve mounted on the Outlet Silencer.
• Check (Non Return) Valve mounted to the outlet port.
• Flange Pack and Air Inlet Pipe Kit.
BELT DRIVE
ASSEMBLY
RELIEF VALVE
(Fitted to outlet silencer)
COMPRESSOR HOUSING
(Incorporating inlet air
silencer and filter)
FAN COVER AND
COOLING AIR INTAKE
(DO NOT OBSTRUCT)
COOLING AIR OUTLET
(DO NOT OBSTRUCT)
INTAKE AIR PIPE
(Refer Note)
Note: The free end of the Intake Air Pipe (89mm bore x 1 metre long) must be located in a
position where it will be free from the ingress of water and other contaminants and the
air supply is cool and dry. An alternative method is to connect the pipe to the vehicle air
inlet stack with minimum of 100mm bore or fit a suitable rain hood. It is the responsibility
of the installer to ensure that this meets the approval of the vehicle manufacturer.

Page 4
Publication 4991460001 (May 2000)
2.1 Lifting and Handling
The D9000 unit weighs approx 300 Kg and should be lifted and installed onto the vehicle
on its delivery pallet by fork lift truck.
2.2 Physical data.
The overall dimensions of the D9000 are shown in fig 2.
720
54
50
10
1DRIVE SHAFT
10 x 8
182
626
246170
35
120
556
858
Detail 'A'
4 x 13mm Holes
90
90
90
90
26
322
Fig 2
OVERALL DIMENSIONS

Page 5
Publication 4991460001 (May 2000)
2.3 Orientation
The D9000 unit is supplied in either Left Hand or Right Hand configurations, Figure 3A
shows how to identify Right or Left hand units.
The D9000 unit can be driven from either of the 2 input shafts provided that the
direction of rotation of the compressor shafts is correct. Refer to the direction of
rotation labels attached to the unit.(Fig 3B)
Fig 3A
Fig 3B
RIGHT HAND
LEFT HAND
RIGHT HAND

Page 6
Publication 4991460001 (May 2000)
3 INSTALLATION
When installing the D9000 unit the following must be checked:-
- The correct rotation of the D9000 rotors.
- The alignment of the D9000 drive and the vehicle PTO is within limits
- The cooling air inlet to the unit is unobstructed.
- The belt drive is installed and aligned correctly.
3.1 Power Requirements
The vehicle Power Take Off (PTO) should be rated for the full power consumption of the
D9000 i.e. 60 Kw. at 3000 rpm input shaft speed (190 Nm. torque at the compressor input
shaft) = 340 Nm at propshaft for standard 1. 78:1 Belt Arm
A belt drive capable of transmitting the required power and with a drive ratio to ensure an
operating speed range of between 1800 and 3000 rpm for the D9000 is required. Consult
your Drum agent for an appropriate belt drive.
3.2 Mounting
The D9000 should be attached to the vehicle chassis via two sections of channel (minimum
4” x 2” or 100 mm x 50 mm). The D9000 machine and bracket assembly can then be then be
bolted to these channels using 8 off M12 bolts and lock nuts.
The axis of the D9000 must be parallel to the vehicle PTO shaft (see figure 5) this can be
achieved by angling the channel. This may result in the D9000 unit being visually out of
alignment with the vehicle chassis.
M12 bolts and lock nuts
(Ensure that the Bolt heads
are on the outside of the
bracket, this will prevent
any fouling of the drive
belts)
VEHICLE CHASSIS
Fig 4
Top Bolt centre must be a minimum
of 50mm below top of channel
mounting legs. Max hole size is
15mm for M14 bolts
30mm Max
Delivery Pallet must remain
attached until machine is
secured to chassis

Page 7
Publication 4991460001 (May 2000)
=
=
3.3 Alignment
The D900 input drive and the vehicle Power Take Off (PTO) should be parallel within
1 degree and positioned such that the linking drive shaft makes an angle of no greater than
12 degrees.
Note: Refer to PTO manufacturers literature when installing.
12° Max
Figure 5
3.4 Belt Drive.
The D9000 unit is designed to be belt driven from the vehicle PTO. A belt drive unit suitable
for the installation and capable of transmitting the required power can be ordered via your
Drum dealer. Figure 6 shows the components of a typical Drum belt drive unit. The belt drive
can be fitted to either of the two shafts on D9000 but the direction of rotation of the D9000 unit
must be maintained (see section 2.3).
When ordering the belt drive the following information will be required:-
•The centre distance between the D9000 driven shaft and the PTO driver shaft.
•The angle of inclination of the belt drive to the horizontal.
•Required step-up ratio (standard is 1.78 : 1).
Belt Drive Installation.
The Belt Arm Assembly must be fitted AFTER the D9000 unit has been fitted to the chassis
and not whilst the Compressor is on its delivery pallet. The pallet is not designed to allow the
lifting of both Compressor and Belt Arm Assembly.
Assemble the inner Arm (1), Outer Arm (2), Outer Bearing Housing (3), and spacer (7) onto
the D9000 compressor at the required side and angle of inclination. (Refer Fig 6, Page 8).
Note: The driver pulley is factory fitted in a mid position and may need adjustment when
checking the alignment of the pulleys.
Fit Driven Pulley onto D9000 Drive Shaft using Shaft Key. Position pulley to acheive the best
possible taper lock, and lock onto the drive shaft using the stud, securing nut and washer.
Loosen M10 setscrews (4)clamping the outer arm to the inner arm, slide the outer arm so the
centre distance between the compressor and the bearing housing shafts is at a minimum.
Re-tighten any two of the setscrews to hold this position.
Flange faces to be parallel within 1°

Page 8
Publication 4991460001 (May 2000)
6
Driven Pulley
1
2 3
4
5
Driver Pulley
Note: M10 Tapped holes provided on pulley for use with a puller
A piece of steel tubing may be necessary to go over the stud
D= Deflection of belt when pressure
is applied to Tension Taster
Cmm 567 667 702 767 782 812
Dmm 5.6 6.7 7.0 7.6 7.8 8.1
FN 40 40 40 40 40 40
Kg 4.1 4.1 4.1 4.1 4.1 4.1
Lbf 9 9 9 9 9 9
7
Fig 6
Fig 7
F= Force applied to Tension Tester
C= Pulley centre distance
BELT TENSION VALUES