M-D Pneumatics COMPETITOR PLUS 2002 User manual

LEADING THE SEARCH FOR NEW SOLUTIONS
4840 West KearneyStreet, P. O. Box 2877
Springfield, Missouri USA 65801-2877
Tel [phone] 825-6937 Fax[phone]
www.mdpneumatics.com
Rotary Positive Blowers
COMPETITOR PLUS rotar
y
blowers are desi
g
ned to be
interchan
g
eable with e
q
uivalent sizes of Roots Universal
RAI®, and man
y
Sutorbilt® California Series B and F, and
Le
g
end™ Series L and P blowers. COMPETITOR PLUS
models are rated up to 15 PSIG dischar
g
e pressure or 16” H
g
dr
y
vacuum.
In addition to interchan
g
eabilit
y
, M-D has improved on
existin
g
desi
g
ns with the followin
g
superior features ordinaril
y
found onl
y
on premium blowers:
Helical Gearing
COMPETITOR PLUS blowers are timed with hardened,
precision helical
g
ears, ke
y
ed to the rotor shafts, not taper fit
spur
g
ears offered b
y
other manufacturers which have
g
reater
backlash, and can slip and lose timin
g
. Helical
g
ears are also
q
uieter, reducin
g
mechanical noise.
Stronger Bearings
COMPETITOR PLUS blowers include double row ball
bearin
g
s at the
g
ear end, stron
g
er than sin
g
le row ball
bearin
g
s offered b
y
other manufacturers. Drive shaft bearin
g
is c
y
lindrical roller t
y
pe for additional stren
g
th a
g
ainst side
loadin
g
from V-belt drives. As a result of this superior desi
g
n,
COMPETITOR PLUS blowers offer an avera
g
e desi
g
n
bearin
g
life of up to 50%
g
reater than models offered b
y
other
manufacturers.
Rotors with Integral Shafts
COMPETITOR PLUS blowers include precision machined
ductile iron rotors with lar
g
e, inte
g
rall
y
cast shafts, not press
fit and/or pinned shafts offered b
y
other manufacturers, which
can loosen over time and cause rotor clash. All rotors are
d
y
namicall
y
balanced for vibration-free rotation.
Positive End Clearances
End clearances are positivel
y
established at the blower
g
ear
end, eliminatin
g
the risk of shiftin
g
end clearances when
installin
g
or removin
g
drive components. This also eliminates
the need for those special fork and saddle tools re
q
uired b
y
other brands to reset end clearances.
Polished Sealing Surfaces
All shaft surfaces in contact with sealin
g
members are
polished to reduce seal wear and risk of leaka
g
e.
Individually Tested
Ever
y
COMPETITOR PLUS blower is factor
y
tested to assure
y
ou of the hi
g
hest
q
ualit
y
. While some manufacturers perform
onl
y
sample testin
g
, M-D
g
oes the distance to insure that
y
our
blower meets our ri
g
id ISO 9001 re
g
istered
q
ualit
y
standards.
ISO 9001 Registration
COMPETITOR PLUS blowers are manufactured under M-D’s
ISO 9001 re
g
istered
q
ualit
y
assurance pro
g
ram, the first
American manufacturer of rotar
y
blowers to
g
ain such
international reco
g
nition.
Warranty
Ever
y
COMPETITOR PLUS blower is backed b
y
M-D’s limited
warrant
y
for a period of 18 months after installation or 2
y
ears
after ori
g
inal blower shipment, whichever occurs first.
Versatility
COMPETITOR PLUS blowers can be field converted from
horizontal to vertical flow, or vice versa, without an
y
special
tools or
additional components.
Metric Availability
All COMPETITOR PLUS blowers are available with metric drive
shaft and process connections.
Worldwide Sales and Service
With sales offices and service facilities located on six continents,
y
ou can be assured of availabilit
y
and service for
y
our
COMPETITOR PLUS blowers.
Material Specifications:
Housin
g
: Cast iron
End Plates: Cast iron
End Cover: Cast iron
Rotors: Ductile iron
Shafts: Ductile iron cast inte
g
rall
y
with rotors
Bearin
g
s: Gear end - Double row ball, both rotors
Drive end - C
y
lindrical roller on drive rotor
Sin
g
le row ball on driven rotor
Drive Shaft: Ductile iron, cast inte
g
rall
y
with drive rotor
Gears: Heat treated allo
y
steel, helical cut
Seals: Lip seals on rotor shafts and drive shaft
Lubrication: Oil splash on
g
ear end,
g
rease on drive end
Model
Size Max. Press.
PSI
Max.
Vac.
(in. Hg)
Nominal Min.
RPM @ Max.
Disch. Press.
Nominal Max.
RPM @ Max.
Disch. Press.
Displ.
CFR
2002 12 16 2940 5275 .016
2004 7 14 1480 5275 .032
3003 12 15 2080 3600 .0616
3006 7 12 1150 3600 .102
4002 15 16 1820 3600 .061
4005 10 14 1300 3600 .121
4007 7 14 1000 3600 .160
5003 15 16 1900 2850 .132
5006 10 15 980 2850 .221
5009 7 14 700 2850 .323
6005 15 16 1240 2350 .246
6008 12 16 890 2350 .395
6015 6 12 600 2350 .740

Blower SPEED 2 PSIG 4 PSIG 6 PSIG 7 PSIG 10 PSIG 12 PSIG 15 PSIG Max. Vacuum
Model (RPM) CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP “ Hg CFM BHP
2002 1170
3600
5275
7
46
73
0.3
0.8
1.2 41 68 1.3 1.9 38 64 1.8 2.7 36 63 2.1 3.1 32 59 2.8 4.2 29 56 3.3 4.9
6
14
16
3
28
51
0.3
2.1
3.4
2004 1170
3600
5275
19
97
150
0.4
1.3
1.9
12
89
143
0.8
2.3
3.4 83 137 3.3 4.9 81 134 3.8 5.6
6
14
14
13
69
122
0.6
3.8
5.5
3003 1170
2700
3600
49
143
198
0.8
1.9
2.5
39
133
188
1.4
3.3
4.5
31
126
181
2.1
4.8
6.4
28
122
178
2.4
5.5
7.4 114 169 7.7 10 109 164 9.1 12
10
14
15
27
107
158
1.7
5.4
7.7
3006 1170
2700
3600
86
242
334
1.2
2.8
3.8
72
228
320
2.3
5.2
7.0
62
218
310
3.3
7.6
10
57
213
305
3.8
8.9
12
10
12
14
56
202
283
2.7
7.5
12
4002 880
1760
3600
34
87
198
0.6
1.3
2.6
26
79
190
1.1
2.2
4.5
19
73
184
1.6
3.1
6.4
17
70
181
1.8
3.6
7.4 63 174 5.0 10 59 170 5.9 12 164 15
10
14
16
16
57
159
1.3
3.5
8.2
4005 880
1760
3600
70
177
399
1.1
2.2
4.5
55
162
384
2.0
4.1
8.3
44
150
373
3.0
5.9
12
39
145
368
3.4
6.9
14 132 355 9.6 20
8
13
14
47
127
349
2.0
63
13
4007 880
1760
3600
93
234
527
1.4
2.8
5.7
74
214
508
2.6
5.3
11
59
199
493
3.9
7.7
16
52
193
486
4.5
8.9
18
8
12
14
63
176
472
2.6
7.6
18
5003 710
1760
2850
64
203
346
1.0
2.6
4.1
52
191
334
1.6
4.6
7.4
43
181
325
2.7
6.6
11
39
177
321
3.1
7.6
12 167 310 11 17 160 304 13 21 152 295 16 25
10
14
16
37
158
289
2.2
7.5
14
5006 710
1760
2850
108
340
581
1.6
3.9
6.4
87
319
560
3.0
7.3
12
71
303
544
4.3
11
17
65
297
537
5.0
12
20 278 519 17 28
10
14
15
62
263
496
3.6
12
21
5009 710
1760
2850
173
513
865
2.2
5.5
8.9
151
490
842
4.2
10
17
133
472
824
6.2
15
25
125
464
816
7.2
18
29
10
12
14
122
445
779
5.1
15
28
6005 710
1760
2350
129
387
532
1.8
4.5
6.0
110
368
513
3.3
8.3
11
95
354
499
4.9
12
16
89
347
492
5.6
14
19
72
330
476
7.9
20
26 160 304 23 31 307 452 29 38
12
16
16
73
300
445
4.8
16
21
6008 710
1760
2350
207
621
854
2.7
6.8
9.1
176
591
824
5.2
13
17
153
568
801
7.6
19
25
143
557
790
8.9
22
29
116
530
764
13
31
41 515 748 37 50
12
16
16
117
481
714
7.5
25
33
6015 710
1760
2350
387
1164
1601
4.9
12
16
330
1107
1544
9.5
23
31
286
1063
1500
14
35
46
8
12
12
300
996
1433
9.3
34
46
Performance
Pressure performance is based on inlet conditions
of 14.70 PSIA and 70oF.
Vacuum performance is based on inlet temperature
of 70oF and discharge pressure of 14.70 PSIA.
In conjunction with our program of continuous
testing and upgrading, all specifications are subject
to change without notice.
All data are approximate. Request a quotation for
your specific application.
Your Local M-D Sales Professional is:
LEADING THE SEARCH FOR NEW SOLUTIONS
4840 West KearneyStreet, P. O. Box 2877
Springfield, Missouri USA 65801-2877
Tel [phone] 825-6937 Fax[phone]
www.mdpneumatics.com
Model
Size A B C D E H J1 J2 K L1 L2 N1 N2 N3 P R S V
2002
2004 9.75 11.75 4.63 5.63 2.63 3.63 2.50 1” NPT 2” NPT 5.00 7.00 6.88 9.69 3.13 5.13 5.13 3.75 6.25 3.75 9.38 1.25 5.00 .625
3003
3006 12.19 14.56 5.94 7.13 3.75 4.94 2.50 2” NPT 2½” NPT 7.63 10.00 8.94 12.81 3.94 7.25 7.25 5.00 8.50 3.75 12.19 1.75 6.75 .750
4002
4005
4007
12.56
15.31
17.06
5.88
7.25
8.13
3.69
5.06
5.94 3.00 1½” NPT
2½” NPT
3” NPT
7.25
10.00
11.75 10.63 15.13 4.38 8.00 8.00 6.25 10.25 5.00 13.69 2.00 8.25 .875
5003
5006
5009
14.88
17.50
20.50
7.00
8.31
9.81
4.50
5.81
7.31 3.38 2½” NPT
4” NPT
4” NPT
8.38
11.00
14.00 12.13 17.38 5.38 10.50 10.50 6.75 11.25 6.25 17.19 2.50 8.75 1.125
6005
6008
6015
18.38
21.38
28.38
9.06
10.56
14.06
5.63
7.13
10.63 3.69 3” NPT
5” NPT
6” FLG
10.13
13.13
20.18 15.06 21.69 6.25 17.00 11.00 8.75 14.75 8.75 19.81 3.00 11.75 1.375
Dimensions
Values shown are approximate and should not be used for construction.
Certified drawin
g
s are available throu
g
h
y
our local M-D Sales Professional.
0899

Tuthill Pneumatics
Rotary Positive Displacement
Air Blower
2002 3003 4002 5003 6005
2004 3006 4005 5006 6008
4007 5009 6015
Models
INSTALLATION
OPERATION
MAINTENANCE
REPAIR
01/2001
WARNING
DO NOT OPERATE BEFORE
READING MANUAL.
LEADING THE SEARCH FOR NEW SOLUTIONS
4840 West Kearney Street, P. O. Box 2877
Springfield, Missouri USA 65801-2877
Tel [phone] 825-6937 Fax [phone]
E-mail: [email protected]
www.mdpneumatics.com

!WARNING
!WARNING
SAFETY INSTRUCTIONS
1. Do not operate before reading
the enclosed instruction manual.
2. Use adequate protection,
warning and safety equipment
necessary to protect against
hazards involved in installation
and operation of this equipment.
Do not operate
without guards
in place
Do not touch
hot surfaces
SAFETY WARNING
• Keep hands and clothing away from rotating machinery, inlet and discharge openings.
• Blower and drive mounting bolts must be secured.
• Drive belts and coupling guards must be in place.
• Noise level may require ear protection.
• Blower heat can cause burns if touched.
TUTHILL PNEUMATICS GROUP Springfield, MO USA
NOTICE
The above safety instruction tags were attached to your unit prior
to shipment. Do not remove, paint over or obscure in any manner.
Failure to heed these warnings could result in serious bodily injury
to the personnel operating and maintaining this equipment.
!WARNING
Keep body and
clothing away from
machine openings
Hearing
Protection
Required
!CAUTION
2

TABLE OF CONTENTS
SECTION PAGE
INTRODUCTION 4
OPERATING DATA 4
INSTALLATION 5
LUBRICATION 6
PREVENTATIVE MAINTENANCE 7
STARTUP CHECKLIST 7
TROUBLESHOOTING 8
RECOMMENDED SHUTDOWN PROCEDURE 9
DISASSEMBLY AND INSPECTION 10
BLOWER DISASSEMBLY 10
BLOWER ASSEMBLY 12
MAINTENANCE AND SERVICE SPECIFICATIONS SHEET 14
SPECIAL TOOL DRAWINGS 15
CUTAWAY VIEW AND PARTS LIST 16
WARRANTY STATEMENT 17
SAFETY PRECAUTIONS
For equipment covered specifically or indirectly in this instruction book, it is important that all personnel observe
safety precautions to minimize the chances of injury. Among many considerations, the following should particularly be
noted:
• Blower casing 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, or while subject to accidental starting. Cover
external moving parts with adequate guards.
• Disconnect power before doing any work, and avoid bypassing or rendering inoperative any safety or protective
devices.
• If blower is operated with piping disconnected, place a strong, coarse screen over the inlet and avoid standing
in discharge air stream.
• Avoid extended exposure in close proximity to machinery with high intensity noise levels.
• Use proper care and good procedures in handling, lifting, installing, operating, and maintaining the equipment.
• Other potential hazards to safety may also be associated with operation of this equipment. All personnel
working in or passing through the area should be warned by signs and trained to exercise adequate general
safety precautions.
• Hearing protection may be required depending on silencing capabilities.
CAUTION!
Most COMPETITOR PLUS™blowers are
shipped from the factory in a left hand drive,
vertical flow configuration.
If drive shaft location is changed, the oil level
plug and breather must be relocated to proper
positions, as shown to the right.
Failure to change plug location will result in
blower failure and void the product warranty.

4
INTRODUCTION
CONGRATULATIONS on your purchase of a new Tuthill Pneumatics COMPETITOR PLUS™ Rotary Positive
Displacement Blower from Tuthill Pneumatics Group. Please examine the blower for shipping damage, and if any are
found, report it immediately to the carrier. If the blower is to be installed at a later date make sure it is stored in a clean,
dry location and rotated regularly. Make sure covers are kept on all openings. If blower is stored outdoors be sure to
protect it from weather and corrosion.
COMPETITOR PLUS™ blowers are built to exacting standards and if properly installed and maintained will provide
many years of reliable service. We urge you to take time to read and follow every step of these instructions when
installing and maintaining your blower. We have tried to make these instructions as straghtforward as possible. We
realize getting any new piece of equipment up and running in as little time as possible is imperative to production.
WARNING: Serious injury can result from operating or repairing this machine without first reading the
service manual and taking adequate safety precautions.
IMPORTANT: Record the blower model and serial numbers of your machine in the OPERATING DATA form below.
You will save time and expense by including this reference identification on any replacement part orders, or if you
require service or application assistance.
OPERATING DATA
It will be to the user’s advantage to have the requested data filled in and available in the event a problem should
develop in the booster or the system. This information is also helpful when ordering spare parts.
Model No. __________________________________ V-Belt Size ______________ Length _____________
Serial No. __________________________________ Type of Lubrication:
(Recorded from nameplate on unit) Oil (Gear Case) ______________________________
Startup Date ________________________________ Grease (Drive End) ___________________________
Blower RPM ________________________________ Pressure ___________________________________
Blower Sheave Diameter ______________________ Vacuum ___________________________________
Motor Sheave Diameter _______________________ Any other special accessories with this unit
Motor RPM _______________ HP ______________ ___________________________________________
NOTES:

INSTALLATION
WARNING: Customers are cautioned to provide adequate protection, warning and safety equipment necessary to
protect personnel against hazards involved in the installation and operation of this equipment in the system or facility.
Do not use air blowers on explosive or hazardous gases. Casing pressure must not exceed 25 PSIG (1.72 bar g). Each
size blower has limits on pressure differential, running speed, and discharge temperature, which must not be exceeded.
These limits are shown on the Specification Sheet "Maximum Operating Limits".
LOCATION
Install the blower in a clean, dry, well lighted area if possible. Leave plenty of room around the blower for inspection and
maintenance.
FOUNDATION
We recommend a solid foundation be provided for permanent installation. 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.
Before tightening the bolts, check to see that both mounting feet are resting evenly on the foundation, shim as necessary
to eliminate stress on the base when the bolts are tightened.
Where a solid foundation is not feasible, care must be taken to insure that equipment is firmly anchored to adequate
structural members.
DRIVE
When the blower is V-belt driven the sheaves must be positioned so that the hub face of the blower sheave is not more
than 1/4" (6.5 mm) from the blower drive end plate and the driver sheave is as close to the driver bearing as possible.
Care should be taken when installing sheave onto shaft. The faces of the sheaves should be accurately in line to
minimize belt wear.
Adjust the belt tension to the belt manufacturer’s specifications.
For installations where the blower is to be operated by direct drive, selection of the driver should be such as not to
exceed the maximum speed ratings of the blower. (See Specification Sheet "Maximum Operating Limits.)
A flexible type coupling should be used to connect driver and blower shafts. The two shafts must be aligned within .005"
(.13 mm) T.I.R. (Total Indicated Runout)
PROTECTIVE MATERIALS
Remove protective materials from the shaft.
Remove the protective covers from the inlet and outlet ports and inspect the interior for dirt and foreign material.
WARNING: Keep hands, feet, foreign objects and loose clothes from inlet and outlet openings to avoid injury or
damage if lobes are to be rotated at this point.
LUBRICATION
Do not start up the blower until you are positive that it has been properly and fully lubricated. (See Lubrication Section.)
PIPING
Inlet and outlet connections on all blowers are large enough to handle maximum volume with minimum friction loss.
Maintain same diameter piping. Silencers must not be supported by the blower. Bending moments must be avoided.
Be certain all piping is clean internally before connecting to the blower. We recommend placing a 16-mesh wire screen
backed with hardware cloth at or near the inlet connections for the first 50 hours of use until the system is clean. Make
provisions to clean the screen after a few hours of operation and completely discard it once the system is clean, as it will
eventually deteriorate and small pieces going into the blower can cause serious damage. A horizontal or vertical air
flowing piping configuration is easily achieved by rearranging the mounting feet position.
WARNING: Do not operate equipment without adequate silencing devices since high noise level may cause hearing
damage. (Reference OSHA Standards.)
RELIEF VALVES
We recommend the use of relief valves to protect against excessive pressure or vacuum conditions. These valves
should be tested at initial start-up to be sure they are adjusted to relieve at or below the maximum pressure differential
rating of the blower.
CAUTION: Upon completion of the installation, and before applying power, rotate the drive shaft by hand. It must move
freely. If it does not, look for uneven mounting, piping strain, excessive belt tension or coupling misalignment or any
other cause for binding. 5

LUBRICATION
The bearings at the drive shaft end of the blower are grease lubricated. The timing gears and bearings at the other end
are lubricated by the lower timing gear (when in the horizontal flow configuration) acting as a oil slinger, carrying oil to
the upper timing gear and providing splash lubrication for the bearings. Both timing gears act as stingers when the
blower is in the vertical flow configuration.
Use a good grade industrial type anti-rust, oxidation and foam inhibited, non-detergent oil.
FILLING PROCEDURE
To fill the gear housing, remove the oil breather* (A) and oil level plug (B) on the gear end. Fill the gear housing until
oil drips out of the oil level hole. Replace plugs in their respective holes.
*Models 2002 and 2004 do not have oil breathers. In this case, remove plug to fill.
WARNING: Do not start the blower until you are sure oil has been put in the gear housing.
GREASE LUBRICATED BEARINGS
Service drive end bearings at regular intervals. (See "Suggested Lubrication Intervals for Grease Lubricated Bearings"
below.) Use NLGI #2 premium grade, petroleum base grease with high temperature resistance and good mechanical
stability Using a pressure gun, force new grease into each bearing until traces of clean grease come out of the relief
fitting.
CAUTION: To avoid blowing out the drive shaft seal, do not inject grease too rapidly.
6
SUGGESTED LUBRICATION INTERVALS
FOR GREASE LUBRICATED BEARINGS
SPEED OPERATING HOURS PER DAY
IN 8 16 24
RPM GREASING INTERVALS IN WEEKS
750-1000 7 4 2
1000-1500 5 2 1
1500-2000 4 2 1
2000-2500 3 1 1
2500-3000 2 1 1
3000 and up 1 1 1
LUBRICATION INSTRUCTIONS FOR
OIL LUBRICATED GEARS AND BEARINGS
Add fresh oil as required to maintain proper level. Drain
and refill after the first 100 hours of operation and
thereafter every 1,000 hours of operation under normal
service, more frequently depending on the type of oil
and oil operating temperature. Use a good quality oil.
AMBIENT
TEMPERATURE OIL GRADE OIL VISCOSITY RANGE SSU AT 100° F
Above 90° F SAE 50 1000-1200
32° F to 90° F SAE 40 700-1000
0° F to 32° F SAE 30 500-700
Below 0° F SAE 20 300-500

PREVENTATIVE MAINTENANCE
A good maintenance program will add years of service to your blower.
A newly installed blower should be checked frequently during the first month of operation, especially lubrication. Check
oil level in the gear housing and add oil as needed. Complete oil changes are recommended every 1000 operating
hours, or more frequently depending on the type of oil and oil operating temperature.
The following is recommended as a minimum maintenance program.
7
DAILY MAINTENANCE WEEKLY MAINTENANCE MONTHLY MAINTENANCE
1. Check and maintain oil level, and
add oil as necessary.
2. Check for unusual noise or
vibration (See Troubleshooting on
page 8).
1. Clean all air filters. A clogged air
filter can seriously affect the
efficiency of the blower and cause
overheating and oil usage.
2. Check relief valve to assure it is
operating properly.
1. Inspect the entire system for leaks.
2. Inspect condition of oil and change
if necessary (see page 6)
3 Check drive belt tension and tighten
if necessary.
START-UP CHECKLIST
We recommend that these startup procedures be followed in sequence and checked (P) off in the boxes provided in
any of the following cases:
• During initial installation
• After any shutdown period
• After maintenance work has been performed
• After blower has been moved to a new location
Date Checked
1. Check the unit for proper lubrication. Proper oil level cannot be over-emphasized.
Refer to Lubrication Section.
2. Check Alignment.
For Direct Drive: Check coupling and shaft alignment.
For Belt Drive: Check for proper belt alignment and tension.
3. Turn the rotors by hand to be certain they do not bind.
WARNING: Disconnect power. Make certain power is off and locked out before
touching any rotating element of the blower, motor or drive components.
4. "Bump" the unit with the motor a few times to check rotation and to be certain it turns
freely and smoothly.
5. Start the unit and operate it for 30 minutes at no load. During this time. feel the
cylinder for hot spots. If minor hot spots occur, refer to the Troubleshooting Section.
6. Apply the load and observe the operation of the unit for one hour. Check the unit
frequently during the first day of operation.
7. If minor malfunctions occur, discontinue operation and refer to the Troubleshooting
Section.

TROUBLESHOOTING
Although COMPETITOR PLUS™blowers are well designed and manufactured, problems may occur due to normal
wear and the need for readjustment. The chart below lists symptoms that may occur along with probable causes and
remedies.
8
SYMPTOM PROBABLE CAUSE REMEDIES
Loss of oil. Gear housing not tightened properly.
Lip seal failure.
Insufficient sealant.
Tighten gear housing bolts.
Disassemble and replace lip seal.
Remove gear housing and replace sealant. (See
Disassembly and Inspection section on page 10)
Excessive
bearing or
gear wear.
Improper lubrication.
Excessive belt tension.
Coupling misalignment.
Correct oil level. Replace dirty oil. (See Lubrication section
on page 6)
Check belt manufacturer’s specifications for tension and
adjust accordingly.
Check carefully, realign if necessary.
Lack of
volume. Slipping belts.
Worn lobe clearances.
Speed too low.
Obstruction in piping.
Check belt manufacturer’s specifications for tension and
adjust accordingly.
Check for proper clearances (See Assembly Clearances on
page 14)
Increase blower speed within limits.
Check system to assure an open flow path.
Knocking. Unit out of time.
Distortion due to improper mounting or
pipe strains.
Excessive pressure differential.
Worn gears.
Re-time.
Check mounting alignment and relieve pipe strains.
Reduce to manufacturer’s recommended pressure.
Examine relief valve and reset if necessary.
Replace timing gears (See Disassembly and Inspection
section on page 10)
Excessive
blower
temperature.
Too much or too little oil in gear
reservoir.
Too low operating speed.
Clogged filter or silencer.
Excessive pressure differential.
Elevated inlet temperature.
Worn lobe clearances.
Check oil level. (See Lubrication section on page 6)
Increase blower speed within limits.
Remove cause of obstruction.
Reduce pressure differential across the blower.
Reduce inlet temperature.
Check for proper clearances (See Assembly Clearances on
page 14)
Rotor end or
tip drag. Insufficient assembled clearances.
Case or frame distortion.
Excessive operating pressure.
Excessive operating temperature.
Correct clearances (See Assembly Clearances on page 14)
Check mounting and pipe strain.
Reduce pressure differential.
Reduce pressure differential or reduce inlet temperature.
Vibration. Belt or coupling misalignment.
Lobes rubbing.
Worn bearings or gears.
Unbalanced or rubbing lobes.
Driver or blower loose.
Piping resonance.
Check carefully, realign if necessary.
Check cylinder for hot spots, then check for lobe contact at
these points. Correct clearances (See Assembly
Clearances on page 14)
Check condition of gears and bearings; replace if necessary
Possible buildup on casing or lobes, or inside lobes.
Remove buildup and restore clearances.
Check mounting and tighten if necessary.
Check pipe supports, check resonance of nearby
equipment, check foundation.

RECOMMENDED SHUTDOWN PROCEDURE
TO MINIMIZE RISK OF FREEZING OR CORROSION
When high humidity or moisture is present in an air piping system, condensation of water can occur after the blower is
shut down and the blower begins to cool. This creates an environment favorable to corrosion of the iron internal
surfaces, or in cold weather, the formation of ice. Either of these conditions can close the operating clearances,
causing the blower to fail upon future start-up.
The following shutdown procedure outlined below minimizes the risk of moisture condensation, corrosion and
freezing. Care must be taken so as not to overload or overheat the blower during this procedure.
1. Isolate the blower from the moist system piping, allowing the blower to intake atmospheric air.Operate the blower
under a slight load allowing the blower to heat within safe limits. The heat generated by the blower will quickly
evaporate residual moisture.
2. For carpet cleaning applications, after the work is completed, simply allow the blower to run a few (3-5) minutes
with the suction hose and wand attached. The suction hose and wand will provide enough load to the blower to
evaporate the moisture quickly.
3. For extended shutdown, inject a small amount of a light lubricating oil such as 3-in-One®or a spray lubricant such
as WD-40®into the inlet of the blower just prior to shutdown. The lubricant will provide an excellent protective
coating on the internal surfaces. If using a spray lubricant, exercise care to prevent the applicator tube from getting
sucked into the blower. The applicator tube will damage the blower, most likely to the point that repair would be
required.
August 1999
3-in-One and WD-40 are registered trademarks of WD-40 Company.
9

DISASSEMBLY & INSPECTION
With proper maintenance and lubrication, normal life expectancy for gears, bearings, and seals can be achieved.
However, over a period of time these parts must be repaired or replaced to maintain the efficiency of your blower.
This section is written in a way that will allow you to completely disassemble your blower. The inspection of certain
repairable or replaceable parts is referred to at the point of disassembly where these parts are exposed. If at any
point of inspection, repair or replacement is deemed necessary, appropriate instruction will be given to achieve
these repair or replacement is deemed necessary, appropriate instruction will be given to achieve these repairs or
replacements.
Remove the oil drain plug [18] in the bottom of the gear cover [5] and drain the oil. Take out eight cap screws [16]
and remove the gear cover. It may be necessary to tap the sides with a mallet or wooden block to break the seal
joint.
Gears are not exposed for visual inspection. Items in brackets [ ] are referenced to item numbers on page 16.
Inspect the gears for the following:
• Broken Teeth
• Chipped Teeth
• Uneven Wear
• Excessive Wear
• Any Other Abnormalities
WARNING: Before performing any repair
or replacement, disconnect
and lock out power.
Figure 1. Timing Gear Alignment
Figure 3. Pulling Drive Gear with Bar Puller
Figure 2. Pulling Driven Gear with Jaw Puller
Align reference marks and use puller to pull the driven
gear. (Gear on right side). (Refer to Figure 2 below)
BLOWER DISASSEMBLY
Position blower with the drive gear on the left when
facing the gears. Remove socket head screws and
washers. [tems 29 & 26].
Align timing marks and count four (4) teeth down and
place reference marks on the gears. (Refer to Figure 1
below)
Use puller to remove drive gear. A bar puller (Refer to
Figure 3 below) or jack screws can be used.
Figure 4. Pulling Drive End Plate
Remove shim and spacer. [Items 28 & 30]
Turn blower around and remove grease cover [Item 10]
Remove eight (8) cap screws. [Item 15]
Use jackscrews to remove end plate. (Refer to Figure 4
below)
10

Press rotors out of end plate in press if available. If
press is not available, support end plate and rotors in
the housing. Block up housing and use a soft mallet to
drive the rotors out. (Refer to Figure 5 below)
Using a tube or round bar of a slightly smaller diameter
than the shaft clearance holes in the end plates, tap the
bearings out of the end plates. Bearing retainers [Item
22] must be removed before knocking out the bearings.
(Refer to Figure 7 below)
A jaw type puller can also be used. (Refer to Figure 6
below)
Figure 5. Driving Rotors Out Using Soft Mallet
Figure 7. Tapping Bearings Out of End Plates
Figure 6. Driving Rotors Out Using Jaw Puller
Remove seals from both end plates with a punch or dull
chisel. The seals will be damaged during removal and
must be replaced.
Inspect all parts for wear and or damage.
Clean and inspect all parts for burrs and polish seal
journals with at least 320 grit emery or crocus cloth.
Items in brackets [ ] are referenced to item numbers on
page 16.
11

BLOWER ASSEMBLY
After thorough cleaning of the seal and bearing bores of
both end plates apply a thin coat of sealant on the
outside diameter of the new seals and press them into
the end plate using a tool that will bear on the outer
edge of the seal. Spring side of the seal should be
facing you. Apply a thin coat of grease to the seal lip.
Using the drive end plate as a fixture, support it high
enough so the input shaft of the drive rotor clears the
assembly surface. (Refer to Figure A1 below). Place
rotors in fixture with the drive rotor to the left. (See
Figures A1 and A2 below)
Figure A1. Rotors Assembled on Drive End Plate
Figure A2. Detail of Proper Keyway Positions
(NOTE: Keyway positions are exactly opposite
for models 6005, 6008 and 6015)
DRIVE
DRIVEN
Place end plate [Item 4] on rotors.
Apply a thin coat of lubricant on the rotor shafts and the
inner race of the bearings. Tap the bearings [13] into
place using a tube with a flanged end that will contact
both the inner and outer bearing races. (Refer to Figure
A3 below).
Rotor alignment will be opposite that of Figure A2 on all
6" units (keyway on drive rotor will be up and driven to
the right).
WARNING: Keep hands and loose clothing away from
lobes and gears.
Install bearing retainers [Items 22 & 25] to both
bearings.
Check clearances between the end of the rotors and the
face of the end plate. Refer to assembly clearances
chart on page 14 for proper clearances for your model
blower, and refer to page 13 for procedures for
checking and adjusting clearances.
Figure A3. Tapping Bearings into End Plates
12

If clearances check OK, put a spacer [28] and a shim
[30] on each shaft. Timing shims that were removed
should be put back on the shaft from which they were
removed.
Figure A4. Checking Gear End Clearances
Lubricate shafts and bores on gears. Begin by pressing
on the DRIVE gear. This will be pressed on the drive
rotor, which is to the left.
Start the driver gear on the shaft and align the reference
timing marks and press gear on. Lock gears in place
with cap screw [29] and washer [26]. Turn assembly
over and rest the unit on the cap screws and washers
on the gear end.
Set dowel pins [9] in housing and position housing over
the rotors and fasten with cap screws [15]. Check
housing to rotor clearance. (Refer to Figure A5) A depth
mic can be used.
Set on drive end plate [3] and fasten with cap screws
[15]. (ATTENTION: There are four cap screws [17]
which are used to fasten the feet on.) Lubricate shafts
and bearings. Install the ball bearing [12] on the driven
rotor and the roller bearing [11] on the input shaft.
Install grease cover [Item 10] and drive shaft seal [23].
Install any removed plugs [18] and replace breather [27]
if required.
Items in brackets [ ] are referenced to item numbers on
page 16.
ADJUSTING ROTOR INTERLOBE CLEARANCE
Using feeler gauges take interlobe readings and record
on each side of housing as indicated in Figure A5 below.
By removing or adding shim behind the 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 .006" (.15 mm) will change
the rotor lobe clearance .003" (.08 mm) or one-half the
amount.
EXAMPLE: Referring to Figure A5 below, check the
clearance at AA (right hand reading) and BB (left hand
reading). If AA reading is .009" (.23 mm) and BB
reading .003" (.08 mm) by removing .006" (.15 mm)
shims. the readings will change one half the amount
removed or .003" (.08 mm). AA should then read .006"
(.15 mm) and BB should read .006" (.15 mm). The final
reading should be within .002" (.05 mm) of each other.
To determine the amount of shim to add or remove,
subtract the small figure from the larger. If the right side
is higher than the left side, remove shim. If the right side
is reading lower, add shim.
Figure A5. Checking Gear End Clearances
LUBRICATION, FINAL ASSEMBLY
AND MOUNTING
Pack the bearing cavities with suitable grease. Install
bearing cover plate [10]. Replace front lip seal [23]
taking care not to damage the lip as it passes over the
keyway. Lip must point inward toward the bearing. Apply
a good quality RTV silicone sealant to the inner surface
of the gear cover [5]. Install the gear cover with cap
screws [16] and tighten evenly.
Fill gear cover with oil and grease front-end bearings.
Refer to the Lubrication Section in this manual for oil
and grease specification and filling procedures.
To insure blower has not been distorted during
mounting in the installation, turn the lobes by hand to
make sure they are not making contact prior to
connecting to the driver.
13

MAINTENANCE AND SERVICE SPECIFICATIONS SHEET
ASSEMBLY CLEARANCES
Metric values (mm) are shown in parentheses ( )
All other values are in inches
LOBES TO END PLATES LOBE TO CASING INTERLOBE
MODEL TOTAL
(MIN./MAX.) DRIVE END (MINIMUM) GEAR END (MINIMUM) MINIMUM MAXIMUM MININUM
2002, 2004 .005” / .010”
(.13 / .25) .003” (.08) .002” (.05) .004” (.10) .008” (.20) .006” (.15)
3003, 3006 .005” / .010”
(.13 / .25) .003” (.08) .002” (.05) .004” (.10) .008” (.20) .008” (.20)
4002, 4005,4007 .007” / .012”
(.18 / .30) .004” (.10) .003” (.08) .005” (.13) .009” (.23) .010” (.25)
5003, 5006, 5009 .007” / .012”
(.18 / .30) .004” (.10) .003” (.08) .005” (.13) .009” (.23) .012” (.30)
6005, 6008, 6015 .011” / .015”
(.28 / .38) .008” (.20) .003” (.08) .006” (.15) .010” (.25) .010” (.25)
MODEL FLUID OUNCES (LITERS)
HORIZONTAL
FLOW VERTICAL FLOW
2002, 2004 3.5 (.10) 6.0 (.18)
3003, 3006 6.0 (.18) 16.0 (.47)
4002, 4005, 4007 7.0 (.21) 22.8 (.67)
5003, 5006, 5009 16.0 (.47) 27.6 (.82)
6005, 6008, 6015 28.0 (.83) 52.0 (1.54)
MODEL RPM PRESSURE
PSI (mbar) VACUUM in. Hg (mbar) TEMPERATURE RISE Fo(Co)
2002 5275 12 (825) 14 (475) 225 (125)
2004 5275 7 (480) 14 (475) 185 (103)
3003 3600 12 (825) 14 (475) 170 (94)
3006 3600 7 (480) 14 (475) 115 (64)
4002 3600 15 (1035) 14 (475) 240 (133)
4005 3600 10 (690) 14 (475) 170 (94)
4007 3600 7 (480) 14 (475) 130 (72)
5003 2850 15 (1035) 14 (475) 195 (108)
5006 2850 10 (690) 14 (475) 180 (100)
5009 2850 7 (480) 14 (475) 115 (64)
6005 2350 15 (1035) 16 (540) 250 (139)
6008 2350 12 (827) 16 (540) 240 (133)
6015 2350 6 (415) 12 (410) 130 (72)
14
OIL RESERVOIR CAPACITIES
MAXIMUM OPERATING LIMITS

SPECIAL TOOL DRAWINGS
All dimensions shown are in inches.
MODEL PART
NUMBER A B C D EFG
2000 2200718B 1.560±
.001 1.27± .005 .98± .005 .70± .005 1.10± .005 3.50± .005 3.00± .005
3000 3300718B 2.035±
.001 1.70± .005 1.335± .005 1.015± .005 1.415± .005 3.75± .005 3.00± .005
4000 4200718B 2.425±
.001 2.02± .005 1.61± .005 1.21± .005 1.61± .005 4.50± .005 3.75± .005
5000 5300718B 2.820±
.001 2.42± .005 1.81± .005 1.41± .005 1.81± .005 5.00± .005 4.25± .005
6000 6500718B 3.135±
.001 2.73± .005 2.00± .005 1.605± .005 2.00± .005 6.25± .005 5.50± .005
MODEL PART
NUMBER A B C D EF
2000 2200708B 1.560±
.001 1.24± .005 1.04± .005 .70± .005 1.10± .005 4.00± .005
3000 3300708B 2.035±
.001 1.74± .005 1.54± .005 1.015± .005 1.415± .005 4.37± .005
4000 4200708B 2.425±
.001 1.865± .005 1.665± .005 1.21± .005 1.61± .005 5.25± .005
5000 5300708B 2.820±
.001 2.427± .005 2.227± .005 1.41± .005 1.81± .005 5.68± .005
6000 6500708B 3.135±
.001 2.74± .005 2.54± .005 1.605± .005 2.00± .005 7.00± .005
15

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
1Housing 1 15 Screw, Hex Head 16
2Mounting Foot 2 * 16 Screw, Hex Head 8 **
3Drive End Plate 1 17 Screw, Hex Head 4
4Gear End Plate 1 18 Plug, Oil 3
5Gear Cover 1 19 Relief Fitting 2
6Drive Rotor 1 20 Grease Fitting 2
7Driven Rotor 1 22 Bearing Retainer 4
8Timing Gear 2 23 Lip Seal, Drive Shaft 1
9Dowel Pin 4 24 Lip Seal 4
10 Bearing Cover Plate 1 25 Screw, Hex Head 4
11 Roller Bearing, Drive Shaft 1 26 Washer 2
12 Bearing 1 27 Breather † 1
13 Bearing 2
*Item 2: Models 6005, 6008 and 6015 require (2) each of left and right feet.
** Item 16: Models 5003, 5006 and 5009 require (6) each.
†Item 27: Models 2002 and 2004 requires a pipe plug in lieu of breather.
When ordering parts, use the item number shown, plus your model and serial number.
CUTAWAY VIEW AND PARTS LIST
16

WARRANTY
Subject to the terms and conditions hereinafter set forth and set forth in General Terms of Sale, Tuthill Pneumatics Group (the
seller) warrants products and parts of its manufacture, when shipped, and its work (including installation and start-up) when
performed, will be of good quality and will be free from defects in material and workmanship. This warranty applies only to Seller's
equipment, under use and service in accordance with seller's written instructions, recommendations and ratings for installation,
operating, maintenance and service of products, for a period as stated in the table below. Because of varying conditions of
installation and operation, all guarantees of performance are subject to plus or minus 5% variation. (Non-standard materials are
subject to a plus or minus 10% variation)
THIS WARRANTY EXTENDS ONLY TO BUYER AND/OR ORIGINAL END USER, AND IN NO EVENT SHALL THE SELLER
BE LIABLE FOR PROPERTY DAMAGE SUSTAINED BY A PERSON DESIGNATED BY THE LAW OF ANY JURISDICTION AS
A THIRD PARTY BENEFICIARY OF THIS WARRANTY OR ANY OTHER WARRANTY HELD TO SURVIVE SELLER'S
DISCLAIMER.
All accessories furnished by Seller but manufactured by others bear only that manufacturer's standard warranty.
All claims for defective products, parts, or work under this warranty must be made in writing immediately upon discovery and,
in any event within one (1) year from date of shipment of the applicable item and all claims for defective work must be made in
writing immediately upon discovery and in any event within one (1) year from date of completion thereof by Seller. Unless done
with prior written consent of Seller, any repairs, alterations or disassembly of Seller's equipment shall void warranty. Installation
and transportation costs are not included and defective items must be held for Seller's inspection and returned to Seller's
Ex-works point upon request.
THERE ARE NO WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY WHICH EXTEND BEYOND THE DESCRIPTION
ON THE FACE HEREOF, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS OF PURPOSE.
After Buyer's submission of a claim as provided above and its approval, Seller shall at its option either repair or replace its
product, part, or work at the original Ex-works point of shipment, or refund an equitable portion of the purchase price.
The products and parts sold hereunder are not warranted for operation with erosive or corrosive material or those which may
lead to build up of material within the product supplied, nor those which are incompatible with the materials of construction. The
Buyer shall have no claim whatsoever and no product or part shall be deemed to be defective by reason of failure to resist erosive
or corrosive action nor for problems resulting from build-up of material within the unit nor for problems due to incompatibility with
the materials of construction.
Any improper use, operation beyond capacity, substitution of parts not approved by Seller, or any alteration or repair by others
in such manner as in Seller's judgment affects the product materially and adversely shall void this warranty.
No employee or representative of Seller other than an Officer of the Company is authorized to change this warranty in any way
or grant any other warranty. Any such change by an Officer of the Company must be in writing.
The foregoing is Seller's only obligation and Buyer's only remedy for breach of warranty, and except for gross negligence, willful
misconduct and remedies permitted under the General Terms of Sale in the sections on CONTRACT PERFORMANCE,
INSPECTION AND ACCEPTANCE and the PATENTS Clause hereof, the foregoing is BUYER'S ONLY REMEDY HEREUNDER
BY WAY OF BREACH OF CONTRACT, TORT OR OTHERWISE, WITHOUT REGARD TO WHETHER ANY DEFECT WAS
DISCOVERED OR LATENT AT THE TIME OF DELIVERY OF THE PRODUCT OR WORK. In no event shall Buyer be entitled to
incidental or consequential damages. Any action for breach of this agreement must commence within one (1) year after the cause
of action has occurred.
January, 2001
Product Type of Application
Type Atmospheric Air or Process Air
Without Liquids Present Process Gases Other Than Air, or Any Liquid Injected Application
New 24 months from date of shipment, or 18 months
after initial startup date, whichever occurs first 18 months from date of shipment, or 12 months after initial startup date, whichever occurs first
Repair 3 months from date of shipment, or remaining
warranty period, whichever is greater 3 months from date of shipment, or remaining warranty period, whichever is greater
17

NOTES