Cooper Duroflow 4500 series, Duroflow 4504, Duroflow 4506, Duroflow 4509, Duroflow 4512 Service Manual

Price $5.00

DUROFLOW@

SERIES 4500

BLOWERS

1st Edition

Supersedes

D-9-620

BO11O

SERVICE MANUAL

#

COOPER

Gardner-Denver
Industrial Machine~

Section One:

Section Two:

Section Three:

Section Four:

Section Five:

Section Six:

Section Seven:

Section Eight:

Section Nine:

Section Ten:

Section Eleven:

Section Twelve:

Section Thirteen:

DUROFLOW.

45 Series Blowers

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2

Suggested Equipment and Supplies for a Major Overhaul . . . . . . . . . . . . . . ...3

Teardown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5

Policy Replacement Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..9

Major Parts Cleanup Procedures.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Major Parts Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10

Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11

SpurGear Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...18

Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Lubrication Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...20

Parts Lists, Sectional and Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . ...21

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...23

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...25

SECTION ONE

Introduction

This manual was prepared as a guide for the person in­volved in the maintenance or overhaul of DuroFlow@ 45
Series Blowers utilizing splined rotor shafts and timing
gears. There are two versions, one of which uses spur
gears and the other, helical gears.

The helical gear version is the latest in the evolution of

DuroFlow blower technology. It differs from its prede­cessor, the spur gear version, only in the gear tooth
configuration and the addition of a Belleville spring
behind one timing gear. On the helical gear blower,
rotor timing is accomplished by varying the position of
a lock nut moving one timing gear axially against the
pressure of the Belleville spring washer. This slight
longitudinal movement of the drive gear in relation to
the idler gear changes the angular relationship be­tween the two rotors.

In the spur gear version, rotor timing is accomplished
by selective assembly. A particular set of gears is
matched to a particular set of rotors in order to achieve
the proper angular relationship between the two
rotors.

This manual is concerned primarily with the helical
gear version,

which is currently in production.
Section Eight covers the differences in teardown and
reassembly procedure for the spur gear version.

Each of the four sizes of 45 Series blowers has four
configurations designated by the position of the drive
shaft as viewed from the drive end. The most common
configuration, designated vertical-top (VT), has the
drive rotor above the idler rotor and the airbox inlet

and discharge ducts are at the sides. In the vertical-

bottom (VB) configuration, the drive rotor is mounted
below the idler rotor. In the horizontal-left (H L)config­uration, the drive rotor is to the left of the idler rotor

and the airbox inlet and discharge ducts are at the top

and bottom of the unit. In the horizontal-right (HR)
configuration, the drive rotor is mounted to the right
of the idler rotor.

The VT and HL configurations are identical except for
the position of the oil breather and the oil filler plug
and a change in the mounting plate in the HL. Like­wise, the VB and the HR configurations correspond to

each other with the same differences as the VTand HL.
The VT-HL differs from the VB-HR in having a dif-

ferent oil flinger on the drive end which is mounted on
the drive shaft in the VB-HR version rather than on
the idler shaft as in the VT-HL. Both oil flingers are

identical in the VT-HL version, whereas the drive end

flinger is more deeply dished than thegear end fiinger

in the VB-HR versions.
Since the VT version is the most common of the

various configurations, the illustrations and the tear-

down and reassembly procedures in this manual refer
to the VT configuration. The person involved in
overhauling one of the other versions of the blower

should keep in mind the differences noted in the

preceding paragraphs.

In addition, if overhauling either the HL or HR
versions, it is advisable to use a holding fixture to
secure the blower to the workbench. This can be
obtained from DuroFlow or it can be fabricated as in

Fig. 4.

It is suggested that the appropriate sections of this

manual be read and fully comprehended before any

specific service operation is attempted. Further, the

importance of a clean and adequately outfitted
workshop cannot be overemphasized. The success of
any major blower service effort depends upon

recognition of the fact that virtually every part

contained in the assembly is highly precise, and

hence, is vulnerable to the damaging effects of dirt,

moisture and rough handling.

IMPORTANT NOTICE

In mid-1981, modifications to the 45 Series end plates were made that are not shown in the text of this manual.
Blowers now require only one conventional breather cap. This difference will not affect service procedures.

When properly mounted, the air breather ports on modified blowers are always facing downward, and no
longer require breather caps. If these vent ports are threaded, a breather vent will be inserted. DO NOT PLUG
OR OBSTRUCT THESE AIR VENT PASSAGEWAYS!!

The oil sump breathing is now accomplished through the oil fill port. A hexagonal bushing is inserted into the

oil fill hole, and the blowers’ only breather cap is placed in this bushing to vent the oil sump.

2

A.

B.

c.

SECTION TWO

Suggested Equipment and Supplies for a Major Overhaul

Sturdy 3’ x 6’ workbench, equipped with a 5“ jaw
width, turret type machinist’s vise.

10 ton, 2-jaw, 5-1 /2” reach puller, such as Snap­On CG-270.

Wrenches and PIiers.

1. 12“ adjustable (“Crescent” type).

2. 9/16“ six-or twelve-point box/open end com­bination.

3. 3/8’ orl /2” square drive socket tools.
a. Ratchet handle.
b. 3“ to 6’ extension bar.
c. 9/16’ six-or twelve-point socket.
d. Torque wrench, 1 ft-lb graduations to 50 ft-

Ib [7 mkg], such as Snap-On Nos. TE-50F or
TE-51 F Torqometers.

4. 3/4” square drive socket tools.
a. Ratchet or sliding tee handle.
b. 1-13/16’ six-or twelve-point socket.
c. Torque wrench, 5 ft-lb graduations to 350

ft-lb [50 mkg], such as Snap-On No. TE-352
Torqometer.

Q

Iy

‘\

/:’

MATERIAL - COLD DRAWN

~ SEAMLESS TUBING

2“ O. D, 0.180 WALL

I

1/2” THICK MILD

~; r—2“-7sTEEL PLATE

I

T

3“

WELD

1

L J

——.

———=

252,, J J

&2.82”&

FIGURE 3

OIL SEAL INSTALLATION TOOL

5. Large internal snap ring pliers, such as Waldes

c!

!

I

zWELD

Tru-Arc No. S-6700.

~

i’–

I

I

I ‘~

I

I
I

,1

I

I

I _

Ld

1.64”
FIGURE 2

BEARING SLEEVE INSTALLATION TOOL

STEEL

D. Hammers.

1. 24 ounce ball or cross peen.

2. 3 pound plastic faced or rawhide mallet.

E. Chisels and punches.

1. 5/8” edge width flat chisel, blunted.

2. 5/16” shank diameter pin punch.

3. 118” point center punch.

F. Cleaning and deburring tools and supplies.

1.

2.

3.

4.

5.

6.

7.

Decreasing tank of chlorinated solvent, such as

perch lorethylene.
12 clean shop rags.
Stiff, natural bristle scrub brush.
Wire wheel or brush.
1-1 / 2“ edge width gasket scraper.
8“ half round file, smooth or second cut.
Assorted silicone carbide or aluminum oxide
abrasive paper, in 240, 320 and 400 grits.

G. Measuring instruments.

1. Micrometer caliper, O“ to 1“, graduated in

0.001” [0 to 25 mm graduated in 0.01 mm].

2.

3.

4.

Depth micrometer, 1“ to 2“, graduated in 0.001”
[25 to 50 mm graduated in 0.01 mm].
Dial test indicator (lever contact arm type),
graduated in 0.0005” or 0.001” [0.01 or 0.02
mm], and equipped with magnetic base holder.
12“ x 1/2” feeler stock, 0.002” to 0.015“ in

0.001” increments, [0.04 to 0.40 mm], 2 strips
of each, such as Starrett Series 667.

H. Lubricants and compounds.

1. 2 quarts fresh motor oil, conforming to A.P. I.
Service Specs CC and SE (See Lubrication

Recommendations, Sec. Ten).

2. 1 pound fresh assembly lubricant, such as
molybdenum disulfide grease.

MATERIAL - HOT ROLLED STEEL
MODE L I A“

I

B“

I

c“

4504

I

1.75

Z75 I 6.25

1. Miscellaneous items.

1. 3 wooden blocks, approximately 1-1 /2” x
3-1/2’’ xlo’.

2. Two sturdy C-clamps sized appropriately to
clamp blower mounting plate to work bench.

3. Wooden block approximately 3“ x 6“ x 1 /2” to
1“ thick.

4. Awl.

J. Special tools and fixtures (see sketches).

1.

2.

3.

4.

Rotor sleeve installation tool (Figure’2).
Oil seal installation tool (Figure 3).
Blower holding fixture (Figure 4).
NOTE: Holding fixture is needed only for hori­zontal blowers. If preferred, this can be pur­chased from DuroFlow (See Item 40, Section
Eleven).
Bearing installation tool (Figure 5).

I

I

7

3“

WELD

I

1

,,

.1

,,

.——

E

1

‘2A<

FIGURE 4

HOLDING FIXTURE FOR 4500 SERIES BLOWER

FIGURE 5

BEARING INSTALLATION TOOL

B.

SECTION THREE

Teardown Procedure

A. Preparation.

Before beginning the teardown sequence, the oil
should be drained from the unit. It is also sug-

gested that the usual accumulation of sludgy or
encrusted material be removed from the exterior.
This can best be accomplished by scouring with a
stiff bristle brush and soapy water, followed by a
pressure rinse with water. An acceptable alterna­tive is steam cleaning, if the equipment is avail­able. Because all salvable parts are made of cast
iron (or other ferrous alloy), virtually any heavy

duty, chemical cleaning agents—EXCEPT those
which are ACIDIC—are acceptable. It should be
noted, however, that when water (or steam) is used
in the cleaning process, the unit must be disas­sembled immediately, and blown dry with com­pressed air to prevent rusting of machined sur-

faces.
Teardown sequence.

NOTE: Numbers in parentheses ( ) refer to key
numbers in sectional and exploded assembly
drawings on pages 22 and 23.

1. Separation of the unit into basic subassem-

blies.
a. Securely fasten the unit to the workbench,

gear end facing out, using the mounting or
holding fixture and C-clamps (see Fig. 6).

FIGURE 6

BLOWER SECURED TO WORK STAND WITH “C” CLAMPS

b.

c.
d.

e.

FIGURE 7

REMOVING BREATHER CAPS FROM GEAR END PLATE

NOTE All screw threads on the blower are

standard right-hand threads.

Remove the 2 breather caps from the gear
end plate (7) (see Fig. 7).
Remove eight pipe plugs.
Remove the 14 thru-bolts (4) and 2 cap
screws (5) from the gear end cover (l).
Remove the gear cover (1) from the gear end
plate (7).
NOTE: The gasket used to seal the cover/

end plate seam tends to bond tightly to

FIGURE 8

FOUR CAPSCREWS WITH SPACERS BEING TEMPORARILY REPLACED IN

GEAR END PLATE

5

f.

9.

both surfaces. After bolt and screw re­moval, it. is usually necessary to drive off
the gear cover using the ball peen hammer
and blunted chisel.
Temporarily replace four of the cap screws
(4), two in each housing half, to retain the
gear end plate (7) during subsequent opera­tions.
NOTE: Each cap screw must be bushed
with a spacer to prevent bottoming in the
absence of the gear cover (see Fig. 8).

If the timing gears appear to be undamaged,
it is advisable to check the gear backlash
before removing gears to determine whether
they can be reused (see Fig. 9).

(1)

(2)

(3)

(4)

(5)

(6)

Mount magnetic base dial indicator on
gear end plate with arm extending to­ward drive gear.

Lock idler rotor stationary by wedging a

feeler gage between idler rotor and end
plate.

Place the tip of the indicator arm at ap­proximately the center of the contact
surface on a tooth of the drive gear.

Rock the drive gear by hand and read the

total movement to the nearest .0005 in.

[.012 mm].

Rotate the idler rotor 90° and repeat
measurement three times.
Permissible gear backlash is .0025 to
.0055 in. [.064 to .141 mm].
NOTE: If backlash is outside specified
limits at this point, it does not neces-

sarily mean gears are unusable because
the excessive play could be caused by
worn bearings. However, if backlash is
within limits and there is no apparent
damage, the gears may definitely be
reused.

h. If the timing gears appear to be reusable, it

is advisable to make index marks on the
gears to facilitate rotor timing upon reas­sembly. This can best be done by making
small punch marks on the ends of meshing
gear teeth with a pin punch and hammer

(see Fig. 10).

FIGURE 10

INDEX MARKS ON ENDS OF GEAR TEETH

i. Place wood block between idler rotor lobe

and edge of inlet-discharge opening to pre­vent rotor from turning. Loosen but do not

remove the flexlock nut from each rotor

shaft.

j.

Move to drive end of blower. Locate the
tang of the spider washer (21) which was
bent into slot of lock nut (22). Bend the tang
out of the lock nut slot using pin punch and
hammer (see Fig. 11).

k. Chock drive rotor with wood block. Using

blunted flat chisel and hammer, loosen lock

FIGURE 9

CHECKING TIMING GEAR BACKLASH WITH DIAL INDICATOR

6

nut (see Fig. 12). Use caution not to dam-

age rotor shaft with chisel.

1.

Remove lock nut and spider washer and

discard both as they will not be reused.

FIGURE 12

USING BLUNTED FLAT CHISEL AND BALL PEEN HAMMER TO LOOSEN

m

n.

o.

P.

q.

LOCK NUT

Remove the 14 cap screws (18), 14 lock
washers (6), and two cap screw and lock
washer assemblies (5) from the drive end
cover (30).

Remove the drive end cover. It may be
necessary to use blunted flat chisel and
hammer to loosen cover from end plate.

Remove bearing spacer (20) from drive shaft
(see Fig. 13).
Chock idler rotor with wood block. Remove

flexlock nut (27) from drive end of idler
shaft.

Remove oil flinger (29) and clamp washer

(28) from idler rotor shaft.

FIGURE 13

REMOVING BEARING SPACER FROM DRIVE SHAFT

r.

Remove the drive end plate from the re­mainder of the assembly using soft faced
mallet to loosen end plate from dowel pins

in housing halves (see Fig. 14).
CAUTION: The drive end plate weighs
about 40 pounds. Use care not to drop it.

FIGURE 14

USING SOFT FACED MALLET TO LOOSEN DRIVE END PLATE

s.

Remove the flexlock nut (44) from the gear

end of the drive rotor shaft.

t. Remove the timing gear from the drive rotor

using the gear puller (see Fig. 15). Make
sure oil flinger (29) is turned so as not to
interfere with gear being removed from the

drive shaft.

u.

v.

w

FIGURE 15

USING PULLER TO REMOVE TIMING GEAR

Remove the Belleville spring (48) and dis­card as it will not be reused.
Separate the drive rotor from the gear end
plate (see Fig. 16).
Remove the two cap screws and spacers
holding the upper housing half (12) to the

7

x.

y.

z.

aa.

bb.

cc.

dd .

ee.

gear end plate and remove the upper hous­ing half.

Remove the flexlock nut (44) from the idler
rotor shaft.
Remove the oil flinger (29).
Use gear puller to remove the idler gear (42)

from the idler rotor (32).
Remove the idler rotor from the gear end
plate.

Remove the two cap screws and spacers
holding the gear end plate to the lower
housing half (39).
Remove the gear end plate from the lower

housing half.
CAUTION: The gear end plate weighs

about 35 pounds. Use care not to drop it.

Loosen the C-clamps and invert the lower
housing half on the workbench.
Remove the four cap screws (37) and lock

replaced as a matter of service policy.

(1)

(2)

(3)

(4)
(5)

Securely fasten the rotor in the vise,
using 2 wood blocks to prevent marring
of the contoured surfaces.

Remove the seal ring (13) from the drive
end sleeve (14), using the awl to pry
apart the interlock, and then break the
ring from underneath.

Remove the seal ring (13) from the gear
end sleeve (11), as in Step 2.

Remove shims (15) from rotors.
Only as required in accordance with the
guidelines given under PREFACE, re­move the sleeve(s) from the rotor shaft(s)
using the gear puller.

b. End plate subassembly.

PREFACE: Since all seals and bearings
should be replaced during overhaul as a
matter of service policy, both end plate
subassemblies must be completely disas­sembled internally.

washers (38), and separate the mounting
plate (40) from the lower housing half.

(1)

(2)

(3)

(4)

(5)

(6)

Remove the 2 retaining rings (26) from
their respective bearing sockets, using
the snap ring pliers.

Invert the end plate on the work bench,
and set on 2 oak blocks, so as to provide
3-1 /2” clearance between the plate and
bench, and to clear the edges of the
bearing sockets.
Remove the drive rotor bearing (9) or(l 7)

from its socket, using the ball peen
hammer and pin punch.

Remove the drive rotor oil seal (10) from

its socket, as in Step 3.

Remove the idler rotor bearing (9) or(17)

from its socket, as in Step 3.

Remove the idler rotor oil seal (10) from

FIGURE 16

REMOVING DRIVE ROTOR FROM GEAR END PLATE

2. Separation of the subassemblies into com­ponent parts.

a. Rotor subassembly.

PREFACE: Except in unusual cases, the 4
end plugs in each rotor casting need not be
removed or replaced.
Rotor sleeves need only be removed from
their respective shafts for the purpose of
rotor or sleeve salvage.
The 2 iron seal rings carried in the rotor
sleeves should always be removed and

c.

d.

its socket, as Step 3.
Housing half subassembly.
Except in unusual cases, the 4 dowel pins

(34) and 2 ferrules (35) in each housing half

end surface need not be removed or re-

placed. However, the 2 “O” rings (36) car-

ried on the ferrules of each housing half
shou Id always be replaced as a matter of
service policy.

Drive end cover.
(1)

(2)

Place cover on two wood blocks gasket
side up. With hammer and punch drive
out the seal (25). Discard seal as it will
be replaced.
Normally, there is no reason to remove

the two dowel pins (34) which are
pressed into the cover.

8

SECTION FOUR

Policy Replacement Items

It is suggested that the following parts be replaced savings when possible consequences are considered.
each time the 45 Series blower is disassembled re- It is not necessary to order these parts individually, as
gardless of apparent or measured condition. This

DuroFlow offers a factory service parts kit for the 45

merely reflects sound service policy in that the reuse

Series, splined shaft blower.

of these parts cannot be justified on the basis of cost

Item No. Description Qty. Per Unit

Item No.

Description Qty. Per Unit

9

Roller Bearing

2

22

Lock Nut 1

10 Oil Seal

4

25 Oil Seal

1

13 Seal Ring 4

31

Gasket

2

15 Shim .002—.003— As

36

0 Ring

4

.005—.007—.01 O” Required

46 Gasket

2

17 Ball Bearing 2

48

Belleville Spring

1

21 Lock Washer 1

SECTION FIVE

Major Parts Cleanup Procedures

A. Rotors.

1.

2.

3.

4.

5.

6.

Dip in decreasing tank agitating and brushing
to remove grease and oil.
Sandblast or wirebrush as necessary to remove
scale from rotor lobes. If sandblasting, mask
bearing sleeves, bearing spacers, and shafts

with rubber hose or tape to prevent erosion.

Lightly wet polish the bearing sleeves, bearing

spacers, and rotor shafts with crocus cloth.
Any burrs on rotor or shaft should be removed
with a file.

Dip again in decreasing tank and blow dry with

compressed air.

If rotor is not to be inspected and reused im­mediately, dip in oil or rust preventative solu-

tion and seal in a clean plastic bag for storage.

B. End plates.

1.

2.

3.

4.

5.

6.

Dip in decreasing tank agitating and brushing
to remove grease and oil.

Sandblast or wirebrush as necessary to remove
scale. If sandblasting, place plugs in seal ring
bores to prevent erosion during blasting.
Lightly wet polish the seal ring bores with 400
grit abrasive paper.
Remove burrs with file.
Dip in decreasing tank and blow dry with com­pressed air.
If end plate is not to be inspected and reused
immediately, dip in oil or rust preventative

solution and seal in clean plastic bag for stor­age.

C. Housing halves.

1.

2.

3.

4.

5.

6.

Dip in decreasing tank agitating and brushing
to remove grease and oil.
Sandblast or wirebrush as necessary to remove
scale.
Wet polish the machined concave surface with
240 grit abrasive paper.
File burrs on machined surfaces.
Dip in decreasing tank and blow dry with com­pressed air. Use particular care to insure that
all foreign matter is purged from oil passages.
If housing is not to be inspected and reused
immediately, dip in oil or rust preventative
solution and seal in clean plastic bag for
storage.

D. Timing gears.

1.

2.

3.

4.

5.

Dip in decreasing tank to remove grease and oil.
Wirebrush as necessary to remove scale.
Remove nicks and burrs with file.
Dip in decreasing tank and blow dry with com­pressed air.
If gears are not to be inspected and reused im­mediately, dip in oil or rust preventative solu­tion and seal in clean plastic bag for storage.

E. Covers.

1. Dip in decreasing tank agitating and brushing
to remove grease and oil.

2.

3.

4.

5.

Scrape gasket surface to remove any remaining

F. Mounting plate, flingers, and external hardware.

pieces of gasket.

1. Dip in decreasing tank to remove grease and

File any burrs on gasket surface.

oil.

Dip in decreasing tank and blow dry with com-

2. File burrs from mounting surfaces of mounting
pressed air. plate.
If covers are not to be inspected and reused im- 3. If parts are not to be reused immediately, store
mediately, dip in oil or rust preventative solu- in clean plastic bag.

tion and seal in clean plastic bag.

SECTION SIX

Major Parts Inspection Procedures

A. Rotors.

The rotors are usually salvable if no significant
degeneration of the contoured or end surfaces has
occurred.

Occasionally, a hard object accidentally passes
through the blower causing localized gouging of
the lobes. This is not necessarily grounds for im­mediate rejection unless the gouging takes place
on the tip sealing vanes. Rotor end surfaces
should be checked for uniformity and smoothness
and should be free of burrs, eruptions, and other
irregularities. If there is evidence of rotor contact
with end plates, housings, or with each other, the
rotor lobe length and width should be measured.

The following table gives lengths and widths for the
various 45 series models (If specifications outside
these limits, contact factory for advice):

Models Length

Width

4504 3.982-3.986 in.

7.372-7.374 in.

[101.14 -101.24 mm]

[187.25 -187.30 mm]

4506 5.978-5.982 in.

7.372-7.374 in.

[151.84 -151.94 mm]

[187.25 -187.30 mm]

4509

8.976-8.982 in.

7.372-7.374 in.

[228.00 -228.14 mm] [187.25 -187.30 mm]

4512 11.971-11.977 in.

7.372-7.374 in.

B.

c.

[304.07 -304.22 mm]

[187.25 -187.30 mm]

End plates.
The end plates are usually salvable if the planar air
box and seal ring bore surfaces appear undam­aged. As with the rotors, moderate localized goug-

ing of the air box surface is allowable but is not
usually found without more extensive damage to
surrounding areas. Ring bore condition, however,

is critical. No visible evidence of surface finish
disturbance is allowable. If seizure of the rotor
group had occurred during operation, the end

plates should be checked for cracks.
Housing halves.

The housing halves are usually salvable if the

D.

E.

F.

G.

cylindrical air box surfaces appear undamaged. As
with the end plates, the housing halves should be
checked for cracks if seizure had occurred during
operation.

Timing gears.
The timing gears are usually salvable if the mesh­ing teeth show no evidence of profile degenera­tion. The gear teeth are cut with a slight spherical
crown so that small errors in axial rotor alignment
can be tolerated. This produces a tooth contact
pattern that is characteristically elliptical and
somewhat more polished than that of the sur­rounding tooth surface. To determine whether gear
tooth wear has gone beyond acceptable limits, it
is necessary to check the backlash when the pump
is reassembled.

Covers.

The gear end and drive end covers are nearly al­ways salvable provided there are no cracks since
there are no wearing surfaces. The seal bore of
the drive end cover should be examined for
smoothness.

Mounting plate and external hardware.
The mounting plate is nearly always salvable pro­vided it is not cracked or severely bent. If it is

bent, but can be straightened so that the mounting

holes line up, it may be reused. External hardware
can be reused provided the threads are good and
the heads of screws and plugs are not too severely
deformed. Exceptions to this are the spider type

lock washer and external lock nut on the drive
shaft which should always be replaced as a matter
of service policy. The oil gage plug and breather
filters should also be replaced.

Flingers.
Usually salvageable, but if any cracks or surface
damage around the center hole exists they should
be replaced.

10

SECTION SEVEN

Assembly Procedure

A.

B.

Preparation.
All metallic parts should be rinsed in clean mineral
spirits to remove any residual traces of dirt or fil­ings from deburring operations. It is also sug­gested that all tools to be used in the reassembly
operation also undergo a solvent wash, so as to
eliminate yet another

source of contain ination.

Following solvent wash, the parts and tools should
be blown dry with clean compressed air.

The elastic rotor shaft seals (1O)and (25) shou Id be

immersed in fresh motor oil of the type used in the
blower fora period of at least two (2) hours prior to

installation in the end plates. This will allow the
elastomers to absorb sufficient oil to prevent
accelerated early wear.
Reassembly sequence.

1. Rebuilding component parts into basic sub­assemblies.
a. Rotor subassembly.

If the sleeves were removed as described in
Section Ill, proceed as follows:

(1)

(2)

(3)

(4)

Lightly coat the gear end rotor shaft and
the bearing sleeve (11) bore with assem­bly lubricant.

Install the bearing sleeve (11) on the
gear end rotor shaft, using the rotor
sleeve instal Iation tool and ball peen

hammer to drive the sleeve tightly onto

its seat.

NOTE: The face of the seal ring end of
the sleeve is notched out in two places
to provide clearance for tips of the mat-

ing rotor lobes. Therefore, the sleeve

must be installed in such a position that
the valley sections of its rotor are both
totally encompassed by a notch on both

sides.

Lightly coat the drive end rotor shaft
and the bearing spacer (14) bore with
assembly lubricant.

Install the bearing spacer (14) on the

drive end rotor shaft, as in Step (2)

above.

If sleeves were not removed, or after rein­stalling them:
(5) Coat the seal ring groove with assembly

lubricant. Install and couple the seal ring

(13) on the bearing sleeve (11).

(6) Install and couple the seal ring (13) on

the bearing spacer (14), as in Step (5)
above.

b. End plate subassembly.

(1)

(2)

(3)

(4)

(5)

Place one presoaked oil seal (10) on the
oil seal installation tool and instal I the
seal in the id Ier socket of one end plate
(7) or (33), metal side down, using the
bal I peen hammer to drive the seal
securely onto its seat.

Install another presoaked oi I seal in the
drive socket of the end plate, as in Step
(1) above.

Install the idler bearing (9) or(17) in the
idler socket of the end plate using the
bearing instal Iation tool and ball peen
hammer to drive the bearing tightly onto
its seat.
NOTE: Install roller bearings in gearend
plate and ball bearings in drive end plate
(drive end plate is thicker).

Install the drive bearing (9) or (17) in the
drive socket of the end plate, as in Step
(3) above.
Install the 2 retaining rings (26) in their
respective bearing sockets, bevelled
side out, using the snap pliers (see Fig.

17). Make certain the snap rings are
properly seated in their grooves.

FIGURE 17

INSTALLING RETAINING RING

c. Housing half subassembly.

Assuming that the 4 dowel pins (34) and 2

ferrules (35) were not removed, install the 2

“O” rings (36) on the ferrules (35).

d. Drive end cover (30).

11

Invert cover and place on wood blocks
gasket side down. Wipe excess oil from O.D.
of presoaked seal (25). Place seal in its bore
with metal face up and tap with plastic
mallet to seat securely.

FIGURE 17A

MEASURING FROM AIRBOX SURFACE TO INNER RACE OF

BALL BEARING

2. Final assembly.
a. Place lower housing half assembly (39) on

bench with cylindrical air boxsurfacedown.
Place mounting plate (40) on housing half,

align holes, and

secure with four cap
screws (37) and four lock washers (38).
Torque cap screws to 50 to 60 ft-lb [7.0 to

8.3 mkg].

FIGURE 17B

MEASURING FROM END OF BEARING SPACER TO END OF ROTOR LOBE

b.

c.

Model
4504

4506
4509
4512

d.

NOTE: The lower housing half differs from

the upper housing half in that the lower half
has one through hole from end to end while
the upper half has two through holes.

Invert assembly and secure mounting plate
to workbench with “C” clamps.
The clearance between the air box surface
of the drive end plate and the drive end of
the rotors is controlled by placing shims of
the required number and thickness on the
drive end of each rotor between the bearing
spacer and the inner race of the ball bear­ing. The procedure for determining the shim
thickness required for each shaft is as fol­lows. Using depth micrometer, measure the
distance from the planar air box surface to
the inner race of the double row ball bearing
reading to the nearest .0005 in. (see Fig.
17A). For the corresponding shaft, measure
from the outer end of the bearing spacer to
end of the rotor lobe reading to the nearest
.0005 in. (see Fig. 17B). The first measure­ment minus the second measurement plus
the appropriate drive end clearance speci­fied in the table below is the total shim
thickness required. (If specifications are
outside these limits, contact factory.)

Drive End

Gear End

Minimum Clearance Minimum Clearance
.005 in. [.127 mm] .006 in. [.152 mm]

.005 in. [.127 mm]

.010 in. [.254 mm]
.007 in. [.178 mm] .014 in. [.356 mm]
.007 in. [.178 mm] .016 in. [.406 mm]

Assemble the required shim stacks, read­ing the micrometer caliper to the nearest

0.0005” across the total lamination of
shims to be used, so as to reduce additive
error.
NOTE: Always use the least number of
shims necessary to obtain the required

FIGURE 18

ASSEMBLING SHIMS TO DRIVE END OF DRIVE ROTOR SHAFT

12

stack thickness, as this reduces the ap­parent loss later produced by retaining nut

compression.

e. Install the assembled shim stacks (15) on

their respective drive end rotor shafts (see

Fig. 18).

f. Install the drive end plate to the lower

housing half with two cap screws (18) using
a 1 /2-13 nut spacer under the head of each
cap screw (see Fig. 19).

Torque cap screws to approximately 30 ft-lb

[3.9 mkg].

FIGURE 19

TWO CAPSCREWS WITH SPACERS USED TO TEMPORARILY FASTEN

DRIVE END PLATE TO LOWER HOUSING HALF.

g.

h.

i.

Brush the bearing spacers on the drive ends

of both rotors with assembly lubricant.

Install the idler rotor to the drive end plate.

Use extreme care in starting the seal ring in
the bore as the ring can easily be broken.
Assemble the drive rotor to the end plate

j.

Install the upper housing half to the drive
end plate. Ferrule with “O” ring must mate
with counterbored hole in end plate. Secure
with two cap screws (18) using a 1 /2-13 nut
spacer under the head of each cap screw
(see Fig. 21). Torque cap screws to approxi­mately 30 ft-lb [3.9 mkg].

FIGURE 21

TWO CAPSCREWS WITH SPACERS USED TO TEMPORARILY FASTEN

UPPER HOUSING HALF TO DRIVE END PLATE

k. Brush the bearing sleeves on the gear ends

of both rotors with assembly lubricant. in­stall gear end plate using care to avoid
damage to the seal rings during assembly.
Secure end plate to housings using six cap
screws with 1 /2-13 nut spacers (see Fig.

22). Torque screws to approximately 30 ft-lb
[3.9 mkg].

1.

Lubricate threads on drive end of each shaft

with assembly lubricant.

FIGURE 22

SIX CAPSCREWS WITH SPACERS USED TO TEMPORARILY FASTEN GEAR

END PLATE TO UPPER AND LOWER HOUSING HALVES

13

m. Assemble clamp washer (28) and oil flinger

punch, tighten lock nut sufficiently to com-

(29) to drive end of idler shaft (see Fig. 23).
Be sure that oil flinger is assembled con­cave side out.

FIGURE 23

ASSEMBLING CLAMP WASHER AND OIL FLINGER TO DRIVE END OF

n.

o.

P.

IDLER SHAFT

Assemble flexlock nut (27) to drive

end of
idler shaft. Place wood block between idler
rotor lobe and inlet or discharge duct to
prevent rotor from turning. Torque nut to

300 ft-lb [42 mkg] (see Fig. 24).

Assemble bearing spacer (20) to drive end

of drive shaft.

Assemble lock nut (22) to drive end of drive

shaft with chamfer facing toward pump
body. Using hammer and blunted flat

FIGURE 24

TIGHTENING LOCK NUTS WITH TORQUE WRENCH

press shim stack (see Fig. 25).

FIGURE 25

TIGHTENING LOCK NUT TO CHECK DRIVE END CLEARANCE

q. Check drive end plate to rotor lobe clear-

ance for

each rotor with feeler gages (see
Fig. 26). (Drive end clearance for each
model is specified in table following Step
c of Final Assembly procedure on page 12).
If clearance is not within specified limits for
each rotor, remove the drive end plate and
add or remove shims as necessary to adjust
clearance. Reassemble and recheck clear­ance.

r.

When drive end clearance is correct,
temporarily remove the snap rings (26) re­taining the drive end bearings.
CAUTION: Failure to remove these rings may

result in damage to the double-row ball bear­ings during installation of the timing gears.

FIGURE 26

CHECKING DRIVE END CLEARANCE WITH FEELER GAGE

14

s. Brush the gear end splines and threads of

both shafts with assembly lubricant. As­semble the idler gear (42) to the idler shaft
with the large diameter boss toward the
blower body. Use plastic or rawhide mallet
to start idler gear onto shaft.

t. Place oil finger on idler shaft with con-

cave side in toward gear.

u. Lubricate flexlock nut (44) and install on

idler shaft. Chock rotor with wood block to
prevent its turning. Tighten lock nut to seat

gear against bearing sleeve. Then back off

lock nut enough to permit oil flinger to turn
freel y.

v. Rotor timing procedure.

On the helical gear blower, rotor timing

(rotor to rotor clearance) is adjusted by a
system in which rotational motion of the
drive rotor is transferred to the idler rotor
by means of two meshed helical gears, each
splined to its respective rotor shaft. The
axial position of the idler gear is fixed as
the gear face butts against the bearing
sleeve and is held there by a lock nut. The
axial position of the drive gear is slightly

adjustable as the drive gear is clamped be-

tween a conical spring washer (Belleville
spring) and a lock nut. Axial movement of

the drive gear, accomplished by tightening
the lock nut against spring pressure,
changes the angular relationship between
the two rotors thereby changing their
timing.

(1) In order to time the rotors, it is first

necessary to start the gears on their

rotor shafts in proper relationship to

each other.

(2) Place Belleville Spring (48) on the drive

FIGURE 27

POSITIONING BELLEVILLE SPRING AND DRIVE GEAR BEFORE

ASSEMBLING TO DRIVE ROTOR SHAFT

FIGURE 28

ROTOR AND SPACER BLOCK POSITION FOR INDEXING GEARS

(AS VIEWED FROM GEAR END)

rotor shaft,

concave side out toward

(3a)

(3b)

gear (see Fig. 27).

If gears are being reused, align the index

marks made on the gears during tear-

down. Make sure that the wide land in

the drive gear spline is aligned with the

missing tooth on the drive rotor shaft.

Start drive gear on rotor shaft using

plastic or rawhide faced mallet far

enough to engage flexlock nut two turns

by hand.

If new gears are used, align rotors paral-

FIGURE 29

STARTING DRIVE GEAR ONTO SHAFT WITH SOFT FACED MALLET

15

approximately 15” (l-1/2 teeth) while

w. When correct rotor timing has been estab-

idler gear and rotor remain stationary.

Iished, the other interior rotor and air box

Push drive gear onto shaft meshing it

clearances should be checked with feeler

with idler gear. Use mallet to move gear

gages (see Fig. 31).

onto shaft far enough to engage flexlock

nut two turns by hand (see Fig. 29).

(4) The two drive end snap rings (26) tem-

porarily removed on page 14 should now
be replaced.

(5) Drive gear onto shaft by turning flexlock

nut. When the inner faces of gears are
aligned, check rotor-to-rotor clearance at
arrows in Fig. 28. If clearance is greater
than .016” continue turning nut until

.016” is obtained. Rotors should then
turn freely.

(6) If tightening drive gear lock nut does not

free rotors, the gears have been im­properly meshed. Remove drive gear, fit

a new Belleville spring, and repeat gear

Q

D

6A

cc

AB

ADB

c

D

c

B

A

m

A B

D

c
c

D

BCA

BA

DD

AB ~

indexing procedure (Item 3b above).

(7) Before making final timing adjustments,

(1)

torque idler gear lock nut to 300 ft-lb

[42 mkg].

(8) When rotors turn freely, it is still neces-

sary to adjust rotor clearances to be

equal on both sides. Refer to diagram in

Fig. 30. Use feeler gages placed be­tween the rotor lobes at position A-A
and B-B to check clearance. Adjust

(2)

clearance by tightening flexlock nut on
drive rotor shaft. One-sixth of a turn of
the nut will change the clearance by

.005 in. [.13 mm]. Adjust so that clear-

ance at A-A is equal to B-B within

(3)

+ .001 in. [.025 mm]. Clearance must be
checked on both sides of each rotor
lobe near each end.

FIGURE 31

POSITIONS OF ROTORS FOR CHECKING INTERNAL CLEARANCE

-------- --

I-ltiul’lt 3U

POSITIONS OF ROTORS FOR CHECKING TIMING

Clearance between tip of one rotor lobe
and valley of other rotor (C-C and D-D)
should be a minimum of .0040 in. [.102
mm]. This is measured with the rotors
perpendicular to each other. It should be
checked several places along the length
of the rotor for each of the four lobe tip
to valley positions.
Clearance between the rotor tips and the
housing halves should be a minimum of
.0040 in. [.102 mm]. It should be
measured at several places along the
length of each of the four rotor lobes.

Gear end rotor to end plate clearance is

measured between the end of each rotor

lobe and the gear end plate. The gear
end clearance for each model is speci­fied in the table on page 12. If the gear
end clearance is not within limits, re­check the drive end clearance (refer back
to Item q.), as gear end and drive end
clearance are interdependent.
CAUTION: These rotor-to-rotor and

rotor-to-air box clearances are extremely
critical. Even though the blower may
turn freely by hand when cold; under
operating conditions, the parts expand,
and the rotors are subject to slight de­flection. If the clearances are not suffi­cient, the rotors may contact each other
or the housing with destructive results.

If the clearances are too great, the

16

x.

y.

z.

aa.

blower may not develop the pressure or
airflow that is required to perform its
function.

Check gear backlash four places at 90°
intervals as described in the Teardown
Sequence (Section Ill, Item B., 1., g.).

NOTE: If any of the four readings are not
within the specified limits, do not proceed
further with assembly. If a new set of gears

does not solve the problem then consider

returning the unit to DuroFlow for credit

towards a remanufactured blower.
After correct gear backlash has been estab­lished, remove the six cap screws and

spacers used to tern porari Iy

secure the gear

end plate to the housing halves.
Assemble gasket (31) to gear end cover(1).
Assemble gasket and cover to gear end

99.

hh.

Insert 14 cap screws (18) and lock washers

(6) and two cap screw and lock washer as-

semblies (5) through holes in cover and end
plate. Torque all cap screws to 28 to 32 ft-lb
[3.9 to 4.4 mkg].
Assemble lock washer (21 ) to drive end of
drive shaft with tangs outward toward end
of shaft (see Fig. 33).

plate with 14 cap screws (4), 14 lock wash-

ers (6) and 2 cap screw and lock washer
assemblies (5). Torque all cap screws to 28
to 32 ft-lb [3.9 to 4.4 mkg] (see Fig. 32).

FIGURE 22

ASSEMBLING SPIDER WASHER AND LOCK NUT TO DRIVE SHAFT

ii. Reassemble lock nut (22) to drive shaft with

chamfer toward blower body. Tighten lock
nut securely with hammer and punch (see
Fig. 34).
NOTE: if blower rebuilding is to be per­formed on a regular basis, a special tool for
the drive rotor lock nut is suggested. A
detailed drawing for the fabrication of this
tool is available from DuroFlow upon re­quest. if the special tool is used, torque
lock nut to 300 ft-lb [42 mkg].

FIGURE 32

ASSEMBLING GEAR END COVER AND GASKET TO END PLATE

bb.
cc.

dd .

ee.

ff .

Move back to d rive end of blower.
Remove lock nut (22) from drive rotor tem­porarily y.

Remove 4 cap screws(18) holding drive end
plate to upper and lower housing halves.
Assemble gasket (31) to drive end cover (30).
Assemble gasket and cover to drive end
plate.

FIGURE 34

TIGHTENING DRIVE SHAFT LOCK NUT SECURELY WITH BLUNTED

CHISEL AND BALL PEEN HAMMER

17

jj. Choose the lock washer tang that best

aligns with a slot in the

lock nut (22). Bend

the tang into the lock nut to prevent lock

nut from backing off (see Fig. 35).

kk. Install oil gage plug (43) in gear end cover.

II. Install two oil breather caps (8) in gear end

cover.

mm. Install the other eight pipe plugs.

nn. If the unit is not to be installed immediately

cover the air inlet and outlet openings to
prevent the entry of foreign material.

SECTION EIGHT

Spur Gear Blowers

As

mentioned in Section 1, the former blower design
utilized spur tooth timing gears rather than helical
tooth gears

in the current design. The only change
(besides the gears) from the former model to the
current model is the addition of a Belleville spring
washer behind the drive rotor timing gear. Therefore,
when overhauling a blower with a reusable set of spur
gears and rotors, it is optional whether the spur gears
are reused or replaced with a set of helical gears and
Belleville spring. If it is desired to reuse the spur
gears, some steps in the teardown and reassembly
procedures will differ from those for the helical gear
type.

Rotor timing with the spur gears is controlled by
selective assembly (matching a particular rotor to a
particular gear). Therefore, it is essential each gear be
replaced on the shaft from which it was taken. After
checking the gear backlash and marking the ends of
the gear teeth for proper indexing as in Section Ill,

Item B., l.,g. and h.;

it is also necessary to mark the
drive gear and idler gear in some way so that they can
be differentiated upon reassembly. This can be done
with the center punch and hammer or with an etching
tool.

The reassembly procedure for a spur gear blower is
identical to that for the helical gear blower except for
the gear assembly and timing. With the spur gears,
assemble the idler gear as in Section Vll, Item B., 2.,
s. Assemble the drive gear to the drive shaft aligning
the gear idex marks which were made prior to
removing the timing gears. Chock the rotors with a
wood block and torque both flexlock nuts to 300 ft-lb
[42 mkg]. Check rotor timing with feeler gages as in
Section Vll, Item B., 2., v., (7). With spur gears the
rotor timing is notadjustable. If the timing is not within
limits, remove the spur gears and replace with a new
set of helical gears and Belleville spring.

18

SECTION NINE

Operating Limitations

DuroFlow 45 Series blowers are designed to be

blower at speeds and pressures above the rated

operated at 4000 RPM maximum and no more than 2:1

maximum will cause premature bearing and seal wear

pressure ratio. The table below gives characteristic

and will void the warranty.

inlet airflow and horsepower requirements for various

CAUTION: Outlet temperatures should not exceed

speeds and pressures. Attempting to operate the

350”F.

OPERATING CHARACTERISTICS

(Data based on standard air at inlet (14.7 psi @ 60”F)

SPEED (RPM)

2000

2500

3000

3500

4000

MODEL Psl

CFM HP

CFM HP CFM HP

CFM HP CFM HP

4504 2

165

2.5

225 3 280 3.5 335

4.5 390 5.5

5

145

5 205 6.5 260 8 315 9 370 11

8 130

8 185

10

240 12

295 14 351 16.5

10 120

9.5 175

12.5

230 15 287

17.5

337

20.5

12 110

11.5

162 15 215 18.5 270 22 325 26

15

150

18 203 23 255 27

308

31.5

4506

2 260

4

340

5 430

6

513

6.5 600 8

5 235

8

320 10

400

12.5

485 14.5 565

16.5

8 215 12

295 16 380 19

460 22.5

540 26

10 200

14.5

285 19 365

23.5 445 28 530 32.5

12 185 17.5

265 23 350

28.5 435

33.5 515 39

15

250 28 349 35

415 41 495 48

4509 2

395 6

525 8 650

9.5 775 11.5

900 13.5

5

360

12.5

480 16

615

19

735 23

8

855 26

330 19

450 24 575 29

700 34

820 39

10

315

23.5

435 29.5 555 36 680 42 800 48

12 290 27

420 35 540 42

660 50 780 57

15

385 43 510 52

630 61 755 70

4512

2

540

8 705 10 870 12

1040 14 1205

16.5

5

480

16

650 20 820 25

980 30 1150 34

8

445

23

610 30 775 37

935 44 1100 51

10 420

28

580 37

745 45 905 54 1065 62

12 400

34 560 44 720 54

880 64 1040 74

15

520 54 680 66

845 78 1010 90

19

SECTION TEN

Lubrication Recommendations

The blower gears and bearings are splash lubricated.

Proper oil level must be constantly maintained to pre-

vent overheating and damage to internal parts.
After installation of the blower, add oil through the oil

fill plug on top of the drive end plate. Fill only until oil

reaches the level midway in the oil gage plug sight
glass in the gear end cover. Approximate oil capacities
are given below.

Vertical-30 oz. [0.9L]

Oil level should be checked daily. Wait three minutes
after shutdown to allow oil to drain down before
reading level at sight glass. Top up if necessary
through oil fill plug. Every 500 hours of operation (or 6
months whichever occurs first) the oil should be
changed.

Oil used in DuroFlow blowers must meet or exceed the
requirements of SAE specifications SE and CC. The
viscosity used depends upon ambient air temperature
and severity of application, i.e., pressure ratio, as in

Horizontal-56 oz. [1.7L]

the following tabie;

AMBlENT AIR TEMPERATURE

–65 F to 40 F

40°F to 110°F

–54 C to 40C

4C to 43C

I

I I

l.Oto 1.7 P.R.

PRESSURE

0 to 10 psig pressure

SAE IOW SAE 20

0 to 10 in. Hgvacuum

1.7t02.0 P.R.

RATIO

10to 15 psig pressure

SAE 20W

SAE 40

10to 15 in. Hgvacuum

For applications outside these limits, consult
DuroFlow. Oils of different brands or types should not
be mixed.

10W4O or 15W40 multigrade oil is recommended for all

ordinary operating conditions.

20

SECTION ELEVEN

Parts Lists, Sectional and Exploded Views

A list of current part numbers is available upon written request from DuroFlow. Alternatively,
replacement parts may be ordered by part number from the Parts List.

dbdb

@d @@b@@@

Sectional View

DuroFlow 45 Series Blowers

VARIABLE PARTS LIST

ITEM

NO.

NAME OF PART

4512

4509 4506 4504

1

12
23
24
32

39
40
46

Top Housing

Shaft Key
Drive Rotor
Idler Rotor
Bottom Housing
Mounting Plate

Gasket

135069

135431 135437

141534

135729 135720

135720 141562

180929 180928

180927 180926

180933

180932 180931

180930

135070

135432 135438

141535

135405

135436

135442 141541

135716

135717

135718 141539

21

Item

No.

1

2
3
4
5
6

7’
8*
9

10

11
12
13
14
15
16’
17
18
19
20
21
22
23
24

Part

Name of Part

Number

Cover-GearEnd . . . .. . . . . . . . .. . . . 135075

SelfTappingScrew. . . . . . .. . .. . . . . . 129309

NamePlate. . . . . . .. . . . . .. . . . . . . . ,,, 143606

Capscrew. . . . . . . . . . . . . .. . . . . . . . . . 134674

Capscrew&L.W.Assy. 132579

Lockwasher. . . . . . . . . . . .. . . . . . .

2917
EndPlate-GearEnd .(137430) 180672

BreatherFilter..........,...,,,. 140887

RollerBearing......,,,,,,...,.. 138113

OilSeal. . . . . . . . . . . ... . . . .. . . . . . . . . 161200

BearingSleeve,. . . . . . . . . . . .. . . . . 138100

HousingHalf-Top ., ,.. Variable

SealRing . . .. . .. . . . . . . . . . .. . .. . . . 139986

BearingSpacer, . . . . . . . . . . . . . .. . . . 134662

Shim . . . . . . . . . . . . . ...135726-7-8and 159076-7

PipePlug(l”) . .(158285) 186545

BallBearing.........,,.,.,,,,,, 138116

Capscrew. . . . . . . . . . . . . .. . . . . . . . . . 134675

Oil Deflector.,,..............,,, 139466

BearingSpacer........,.....,.. 134671

Lockwasher. . . . . . . . . .. .. . . . . . . . 138257

Locknut . . . . . .. . . . . .. . .. . . . . . . . 128040

Key . . . . . . . . . . . . . .. . . . . . . . . . . . . Variable

Rotor-Drive., .,, ,,, . .. . . . . . . . . . Variable

Quantity

Per Blower

1
4
1

14

4

28

(1) 1
(2) 1

2
4
2
1
4
2

As Required

(2)2

2

14

1
1
1
1
1
1

Exploded View

DuroFlow 45 Series Blowers

(Consult DuroFlow for Truck

Mounted Blowers)

Item Part

Quantity

No. Name of Part Number

Per Blower

25
26
27
28

29..
30

31
32
33‘
34
35
36
37
38
39
40
41‘
42
43
44
45*
46
47
48

OilSeal. . . . . . . . . . .. . .. . . . . . . . . ...

SnapRing.....................,,,

FlexlockNut . . . . . . . . . . . . . .. .. . ,,,

ClampWasher, . . . . . . . . . . . . .. . . .

Finger. .. . . . . . . . . . . .. . .. . . . . .

Cover-DriveEnd. . . . . . . . . . . .. . . . .

Gasket . . . . . . . . . . . . . .. . . . . . . . . .

Rotor-idler, .. . . . . . . . . . .. . .. . . . .

EndPlate-DriveEnd. .(137429)

Dowel . . . . . . . . . . .. . .. . . . . . . . . . .

Ferrule . ., . ., .. . . . . .. . . . . . . . . .

“O’’Ring. . . . . . .. . . . . . . . . . . . . . . .. .

CapScrew . . . . . . . . . . . . . . . . . . . . . .,,

Lockwasher. . . . . . . . . . . . .. . . . . .

HousingHalf-Bottom . . ..

MountingPlate(Vertical)
PipePlug(318’’). .,, ,,, ,,, ,,, ,.. .

Gearldler L,H. . . . . .. . . . . . . . . . . . ..,,

Oil GagePlug. . . . . . . . . . .. . . . . . . . . .

FlexlockNut . . . . . . . . . . . . . .. . . .

PipePlug(112’’), ,,, ,,, ,,, ,, .. . . .

Gasket . . . . . . . . . . . . . .. . . . . . . . . . .,,

GearDriveR.H.,,,....,......,,,

BellevilleSpring .. . . . . .. . . . .. . .. ,,,

134870
125606
124793
135766
See

Below

135074

135715

Variable
180673
121880
119034
119058
100963

2675
Variable
Variable

21360
181377
137799
124793

9620
Variable
181378
181069

1

4
1
1

. .

1
2

(1; 1

10

4
4
4
4
1
1

(2) 2

or O
1
1

2

(4) O or 2

2
1
1

* Note - Part Number and/or quantity needed with old style end plates are in parenthesis.

** Flingers

- For V1/HL shaft configurations use 2-134652.
For VB/HR shaft configurations

use 1-134652 and 1-143095.

22

SECTION TWELVE

Troubleshooting Guide—

DuroFlow Positive Displacement Rotary Blowers

Problem or Complaint

Probable Causes

Noisiness Rotor-to-Rotor Contact

Failing Bearing(s)

Failing Gears

Failing Lubricated Coupling or Joint

Loose Attached Hardware

Air Leakage

Belt Flutter

Poor Performance

Restricted Inlet

Down Stream Restriction

Excessive Air-to-Product Ratio

Usual Reasons or Sources

- Rotors Out of Time

- Excessive Pressure Ratio

- Failed Bearing(s)

- Failed Gears

- Faulty Installation

- Nonspec Oil

- Contaminated Oil

- Insufficient Oil

- Oversized Belt Drive

- Improperly Mounted Sheave

- Overtightened Belts

- Misaligned Direct Coupling

- Insufficient Backlash

- Nonspec Oil

- Contaminated Oil

- Insufficient Oil

- Severe Torsional Vibration

- Nonspec Grease

- Contaminated Grease

- Insufficient Grease

- Belt Guard

- Pump Mounting Bracket

- Frame Members

- In/Out Ducting Supports

- Improper Relief Valve Setting

- Blown Gaskets

- Loose Ducting Joints

- Insufficient Static Tension

- Long Span (Center-to-Center) Distance

- Sheave Misalignment

- Severe Torsional Vibration

- Clogged Filter Element

- Undersized Filtration Unit

- Undersized Inlet Pipe or Tubing

- Excessive Inlet Duct Length

- Collapsed Inlet Hose

- Clogged Silo Vent Filter Element

- Undersized Silo Vent Filter

- Undersized Outlet Pipe or Tubing

- Excessive Outlet Ducting Length

- Clogged Diffusion Pads (on Pneumatic Trailers)

- Material Bridging in Feed Hopper

- Insufficient Feeder Speed

- Material Caking at Inlet Nozzle

- Material Caking at Inlet Nozzle or Funnel

23

Leaking Oil

End Cover Seams Not Tight

Oil Foaming

Chronic Fuse

Excessive Motor Amperage
Blowing or Circuit
Breaking

Overheat ing

Erroneous Pressure or Vacuum

- Loose Gauge Connection

Indication

- Gauge Movement Damaged

- Gauge Miscalibrated

- Gauge Tap Too Far from Unit Outlet Port

Air Leakage

- Improper Relief Valve Setting

- Blown Gaskets

- Loose Ducting Joints

Insufficient Rotor Speed

- Wrong Sheave Set

- Wrong Motor Speed

- Slipping Belts

- Insufficient Engine Speed

Excessive Rotor Clearances

- Abrasive Wear of Rotor Surfaces

- Rotors “Lag” Timed

Change in Conveyed Material

- Material More Difficult to Fluidize

- Material of Higher Density

- Moisture Content of Material Too High

Failed Oil Seals

- Foreign Material in Seal Bores

- Faulty Installation

- Nonspec Oil

- Contaminated Oil

- Overheated Rotor Shafts

- Through Bolts Loose

- Gaskets Torn

- Nonspec Oil

- Oil Cavities Overfilled

- Excessive Pressure Ratio

- Excessive Pump Speed

- Line Voltage Droop

- Air Density Increase

- Loose Electrical Connections

- Foreign Material in Air Box
Underrated Fuses
Premature Heater Strip Actuation

- Unusually High Ambient Temperature

- Underrated Heater Strips
Excessive Pressure Ratio

- Clogged Filter Element

- Undersized Filtration Unit

- Undersized Inlet Pipe or Tubing

- Excessive Inlet Duct Length

- Collapsed Inlet Hose

- Clogged Silo Vent Filter Element

- Undersized Silo Vent Filtration Element

- Undersized Outlet Pipe or Tubing

- Excessive Outlet Ducting Length

- Clogged Diffusion Pads (on Pneumatic Trailers)

- Wrong Sheave Set

- Wrong Motor Speed

- Slipping Belts

- Insufficient Engine Speed

Insufficient Rotor Speed

24

SECTION THIRTEEN

WARRANTY

GARDNER-DENVER INDUSTRIAL MACHINERY

DUROFLOW

BLOWERS

1800 GARDNER EXPRESSWAY

QUINCY, IL 62305-4024
TEL: [phone]“ FAX [phone]

GENERALPROWSIONS AND LIMITATIONS

Industrial Machinery (the “Compan ‘) warrants to each
original retail purchaser (“Purchaser of its new roducts
from the Company or its authorized distributor that such
products are, at the time of delivery

to the Purchaser, made

with good material andworkmanship. No warranty ismade
with respect to:

1.

2.

3.

4.

5.

An product which has been repaired or altered in

Ksuc a way, in the Company’sjudgment, as to affect

the product adversely.

Any product which has, in the Company'sjudgment
been subject to negligence, accidentt unproper

storage, or improper installation or applicatlion.

Any product which has not been operated or main­tained in accordance with normal practice and with
the recommendations of the Company.

Components or accessories manufactured, war­ranted and serviced by others.

Any reconditioned or prior owned product.

Claimsforitems described in(4) aboveshould be submitted
directly to the manufacturer.

WARRANTYPERIOD
The Company’s obligation under thiswarrantyis limited to

repairingor, atits option, replacin durin normalbusiness
hours at an authorized servicefacility of the Company, any

part which initsjudgment proved not towithin theapplicable Warranty Period asfollows:
BAREBLOWERS
Basic bare blowers consisting of all parts within, are war-

ranted for 12 month from date of initial use or

18 months

from date of shipment to the first purchaser, whichever
occurs first.

Any disassembly or partial disassembly of the blower, or
failure to return the "unopened"blower per Company in­structions, will be cause for denial of warranty.

OTHER COMPONENTS
All other components are warranted for 12 months from

date of initial use or

18 months from date of shipment to first

purchaser, whichever comes first.

LABORTRANSPIRATION AND INSPECTION
The Company will provide labor, by Company repre-

sentative or authorized servicepersonnel, for repair or re-

placementof any product or art thereof which in the

Company's judgmentiS prove not to be as warranted.
Labor shall be limited to the amount specified in the
Company'slabor rate schedule.

Laborcosts in excess of the Companyrate schedule amounts
or labor providedby unauthorized service personnel is not
provide for by thISwarranty.

AUcosts oftransportation of roduct, labororpartsclaimed
not to be aswarrantedand,of repaired orreplacement parts
to or from such service facilities. shall be borne by the
Purchaser.The Company mayrequire the returnof anypart
claimed not to be as warranted to one of its facilities as
designated by Company, transportation prepaid by Pur­chaser, to establish a claim under this warranty.

Replacement parts provided under the terms of the warran­ty are warranted for the remainder of the WarrantyPeriod
of the product upon which installed to the same extent as if
such partswere original components thereof.

DISCLAIMER

THE FOREGOING WARRANTY ISEXCLUSIVE AND
IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO
TITLE THE COMPANY MAKES NO OTHER WAR­RANTiES, EXPRESSED, IMPLIED OR STATUTORY,
INCLUDING ANY IMPLIED WARRANTY OF MER­CHANTABILITY.

THE REMEDY PROVIDED UNDER THIS WARRAN­TY SHALL BE THE SOLE, EXCLUSIVE AND ONLY
REMEDY AVAILABLE TO PURCHASER AND IN NO
CASE SHALL THE COMPANY BE SUBJECT TO ANY
OTHER OBLIGATIONS OR LIABILITIES. UNDER
NO CIRCUMSTANCES SHALL THE COMPANY BE
LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTLAL DAMAGE, EXPENSES, LOSSES
OR DELAYS HOWSOEVER CAUSED.

No statement, representation, agreement, orunderstanding

oral or written, made by any agent, distributor, repre­sentative, or employee o. the Corn any whtch is not con­tamed in this Warrantywill be be g upon the Corn any
unless made in writing and executed by an officer o the
Company.

This warrantyshall not be effective asto any claim which is
not resented within 30 days after the date upon which the
product is claimed not to have been as warranted. Any
action for breach of this warranty must be commenced
withinone yearafter the date upon which the cause of action
occurred.

Any adjustmentmade pursuantto this warrantyshall notbe
construed asan admission bythe Company that anyproduct
was not aswarranted.

25

#

COOPER

Gardner-Denver
Industrial Machinery

For additional information, contact Gardner-Denver Industrial Machinery
Division, 1800 Gardner Expressway, Quincy, Illinois 62305-4024

Telephone [phone] FAX [phone] Telex 404332.

Specificationssubject to change without notice,
COPYRIGHT @ 1991 Cooper Industries, Inc.

Lithoin USA.