Gardner Denver AVS Parts List & Service Manual

GARDNER DENVER�

AIR COOLED

RECIPROCATING

AIR COMPRESSOR

(ENGINE DRIVEN)

MODEL

ASDVMD

PARTS LISTOPERATING ANDSERVICE MANUAL

1–1–5501st EditionJuly, 1995

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MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITHGENUINE GARDNER DENVER

PARTS AND SUPPORT SERVICES

Gardner Denver genuine parts, engineered to original tol-erances, are designed for optimum dependability –––specifically for Gardner Denver compressor systems.Design and material innovations are the result of years ofexperience with hundreds of different compressor ap-plications. Reliability in materials and quality assuranceare incorporated in our genuine replacement parts.

Your authorized Gardner Denver Compressor dis-tributor offers all the backup you’ll need. A worldwidenetwork of authorized distributors provides the finestproduct support in the air compressor industry.

Your local authorized distributor maintains a large inven-tory of genuine parts and is backed up for emergencyparts by direct access to the Gardner Denver MachineryInc. Master Distribution Center (MDC) in Memphis, Ten-nessee, USA.

Your authorized international servicing distributor cansupport your Gardner Denver air compressor with theseservices:

1. Trained parts specialists to assist you in selectingthe correct replacement parts.

2. A full line of factory tested AEON� compressor lu-bricants specifically formulated for use in GardnerDenver compressors.

3. Repair and maintenance kits designed with thenecessary parts to simplify servicing your com-pressor.

Authorized international servicing distributor ser-vice technicians are factory–trained and skilled incompressor maintenance and repair. They are readyto respond and assist you by providing fast, expertmaintenance and repair services.

For the location of your local authorized Gardner Denver Air Compressor dealer refer to the local yellowpages of your phone directory or contact:

Distribution Center: Factory:Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.Master Distribution Center 1800 Gardner Expressway5585 East Shelby Drive Quincy, IL 62301Memphis, TN 38141 Phone: (217) 222–5400Phone: (901) 542–6100 Fax: (217) 223–5897Fax: (901) 542–6159

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Compressor MODEL,Method of Cooling, HORSEPOWER and SERIAL NUM-BER (see nameplate on unit). Serial Number is alsostamped on top of the cylinder flange to the right of theinlet housing.

All orders for Parts should be placed with the nearestauthorized distributor .

Where NOT specified, quantity of parts required per com-pressor or unit is one (1); where more than one is required

per unit, the quantity. SPECIFY EXACTLY THE NUM-BER OF PARTS REQUIRED.

DO NOT ORDER BY SETS OR GROUPS.

To determine the Right Hand and Left Hand side of a com-pressor, stand at the motor end and look toward the com-pressor. Right Hand and Left Hand are indicated in par-enthesis following part name, i.e. (RH) & (LH), whenappropriate.

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TABLE OF CONTENTS

Page

Maintain Compressor Reliability And Performance With Genuine Gardner Denver And Joy CompressorParts And Support Services 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions For Ordering Repair Parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Matrix/Menu 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bare Compressor 5, 6, 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Units 8, 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Mounting & Engine Group 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Group 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Ring Arrangement 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts – Repair Kits 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Dimensions & Running Clearances 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foreword 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions 15, 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation And Operating Instructions 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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INDEX

Adjustment, Main Bearing 19. . . . . . . . . . . . . . . . . . . . . .

Air Filter 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bare Compressor 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing Adjustment, Main 19. . . . . . . . . . . . . . . . . . . . . .

Bearings, Crankpin 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Units 8, 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Group 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control System 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Covers and Guards 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankpin Bearing 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Oil Seal 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive, V Belt 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Mounting & Engine Group 10. . . . . . . . . . . . . . . . .

Duty Cycle 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter, Air 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guards and Covers 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial Starting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation and Operating Instructions 17. . . . . . . . . . .

Location 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating System 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing Adjustment 19. . . . . . . . . . . . . . . . . . . . . . .

Matrix/Menu 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Change 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Quality 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Seal, Crankshaft 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Ring Arrangement 12. . . . . . . . . . . . . . . . . . . . . . .

Prestart Check 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts, Ordering Instructions 1. . . . . . . . . . . . . . . .

Running Clearances, & Standard Dimensions 13. . . . .

Safety Precautions 15, 16. . . . . . . . . . . . . . . . . . . . . . . . .

Seal, Crankshaft Oil 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Parts – Repair Kits 12. . . . . . . . . . . . . . . . . . . . . .

Standard Dimensions & Running Clearances 13. . . . .

Starting, Initial 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Data (Dry) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V–Belt Drive 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viscosity Chart, Figure 1 18. . . . . . . . . . . . . . . . . . . . . . .

Unloader Pilot

Differential Pressure 20. . . . . . . . . . . . . . . . . . . . . . .

Unloading Pressure 20. . . . . . . . . . . . . . . . . . . . . . . .

Unloader Pilot Illustration, Figure 2 20. . . . . . . . . . .

Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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COLUMN 1 – COMPRESSOR MODELA. Air Cooled

COLUMN 2 – LUBRICATION & CRANKCASES. Splash Lube – Cast Iron Crankcase

COLUMN 3 – HORSEPOWERD. 5 HP

COLUMN 4 – CONSTRUCTIONV. Tank Mounted Package – Single Unit – Engine Driven

COLUMN 5 – PACKAGE UNITS – PRESSUREM. 175 PSIG

COLUMN 6 – DESIGN VERSIOND. FOURTH

COLUMN 7 – PACKAGE DRIVERP. Kohler EngineQ. Honda Engine

COLUMN 8 – PACKAGE DRIVER VOLTAGE & STARTER VOLTAGEP. 12 Volt Less Battery

COLUMN 9 – PACKAGE CONTROLX. Constant Speed (Unloader Pilot) with Engine Throttle Control

COLUMN 10 – PACKAGE AFTERCOOLERA. Standard Discharge Piping Only.

COLUMN 11 – PACKAGE RECEIVER SIZEA. 10 Gallon Horizontal – Twin Tank – Low ProfileC. 30 Gallon Horizontal

COLUMN 12 – PACKAGE SUCTION AIR FILTERA. Dry Type – Hooded Filter Silencer9. Less Air Filter

AIR–COOLED COMPRESSORSMODELS ASDVMD – 5 HP ENGINE DRIVEN – MATRIX/MENU

NOTICE TO CUSTOMER – To find the construction options for your com-pressor unit, FILL IN THE BALANCE OF LETTERS OR NUMBERS FROMYOUR UNIT NAMEPLATE.

COLUMN NUMBER:

Follow the line down and over from each space thus filled in to find the ap-propriate construction option with which your machine is equipped. Thenumber ”9” in any column space indicates ”NOT APPLICABLE.” The num-ber ”8” in any column space indicates SPECIAL DESIGN – REFER TO FAC-TORY ORDER TICKET.

A S D V M D P X A__ __ __ __ __ __ __ __ __ __ __ __1 2 3 4 5 6 7 8 9 10 11 12

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Order By Part Number And Description. Reference Numbers For Your Convenience Only.

207ASD810–A(Ref. Drawing)

BARE COMPRESSOR

Ref. No. Name of Part Qty. Part No.

4 PLUG 1 64B4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 TUBE–INTERCOOLER (FIN) 1 200ASD242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SHEAVE 1 202ASD099. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 ROD–OIL LEVEL 1 201ASK491. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 O–RING 1 25AM18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 1/4” GALVANIZED PLUG 1 64AA5G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 VALVE–PRESSURE RELIEF 1 90AR731 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 DECAL 1 200MBV077. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 DECAL 1 211SPH077. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 NAMEPLATE 1 69F64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 GASKET, HIGH PRESSURE 1 202ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 GASKET, HIGH PRESSURE 1 203ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 GASKET, LOW PRESSURE 1 204ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 GASKET, LOW PRESSURE 1 205ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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BARE COMPRESSOR

207ASD810(Ref. Drawing)

CRANKCASE OIL CAPACITY –– 2.6 QUARTS

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Order by Part Number and Description. Reference Numbers for your convenience only.

BARE COMPRESSOR

Ref.No. Name of PartQty. Part No.

1CRANKCASE CAST IRON1203ASD013 . . . . . . 2PAN–OIL1202ASD545 . . . . . . . . . . . . . . . . . . . . . . 3SCREW875LM202 . . . . . . . . . . . . . . . . . . . . . . . 5BUSHING–CONNECTING ROD1203ASD229 . 7CRANKSHAFT1202ASD004 . . . . . . . . . . . . . . . . . 8BEARING ROLLER212C77 . . . . . . . . . . . . . 9SEAL–OIL160G114 . . . . . . . . . . . . . . . . . . . . . 10HOUSING–BEARING1200ASD006 . . . . . . . . . . . 11SHIM1200ASD732 . . . . . . . . . . . . . . . . . . . . . . . . . 12SCREW–HEX FLANGED675A10 . . . . . . . 13 *CONNECTING ROD ASM. L.P.1200ASD2052 . . 14ROD–CONNECTING2204ASD003 . . . . . . . . . . . 15PISTON–AIR1200ATS015 . . . . . . . . . . . . . . . . . . 16PIN–PISTON1200ATS505 . . . . . . . . . . . . . . . . . . 17RING–RETAINING274D45 . . . . . . . . . . . . . 18RING–PISTON265V13 . . . . . . . . . . . . . . . . . 19PISTON RING ASSEMBLY165AM352 . . . . . . 20HEAD–CYLINDER1200ASD007 . . . . . . . . . . . . . 21VALVE–COMPLETE1200ASD529 . . . . . . . . . . . . 22SCREW–FLAT SOC HD1120176 . . . . . . . . 23SCREW–HEX FLANGED8655ED070 . . . . . . . 24WASHER–PLAIN1495F3C . . . . . . . . . . . . . . 26PISTON–AIR1201ATS015 . . . . . . . . . . . . . . . . . .

ØNot shown on drawing.*Includes Reference Numbers 5 and 14 (one (1) each).**Includes Reference Numbers 14 and 67 (one (1) each).

Ref.No. Name of PartQty. Part No.

27PIN–PISTON1201ATS505 . . . . . . . . . . . . . . . . . . 28RING–RETAINING274D45 . . . . . . . . . . . . . 29RING–PISTON365V12 . . . . . . . . . . . . . . . . . 30PISTON RING ASSEMBLY165AM351 . . . . . . 31HEAD–CYLINDER1201ASD007 . . . . . . . . . . . . . 32VALVE–COMPLETE1201ASD529 . . . . . . . . . . . . 33SCREW–HEX FLANGED6655ED070 . . . . . . . 34PLUG–SQHD PIPE164AJ1 . . . . . . . . . . . . . 35ELBOW–TUBE1200ASD262 . . . . . . . . . . . . . . . . 36ELBOW–TUBE186N284 . . . . . . . . . . . . . . . . 40WASHER–FLAT195A8C . . . . . . . . . . . . . . . . 41LOCKNUT1121381 . . . . . . . . . . . . . . . . . . . . . 49NIPPLE–PIPE163C1 . . . . . . . . . . . . . . . . . 58NAMEPLATE1201ASL496 . . . . . . . . . . . . . . . . . . 59BEARING–INSERT4201ASD174 . . . . . . . . . . . . . 61BREATHER–PLUG15L224 . . . . . . . . . . . . . 64DECAL1251EAQ077 . . . . . . . . . . . . . . . . . . . . . . . 66PIN–SPLASH2201ASD102 . . . . . . . . . . . . . . . . . . 67BEARING–NEEDLE112GD24 . . . . . . . . . . . . 68**CONNECTING ROD ASM. H.P.1204ASD003A . . 69GASKET–OIL PAN1206ASD715 . . . . . . . . . . . . .

ØTAG–INSTRUCTION1200ATS304 . . . . . . . . . . .

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COMPRESSOR UNITS


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Order by Part Number and Description. Reference Numbers for your convenience only.

COMPRESSOR UNITS

10 Gallon 30 GallonRef. Twin Receiver ReceiverNo. Name of Part Qty. Part No. Part No.

301 GUARD–DRIVE 1 204ASD120 204ASD120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 BRACKET–FORMED 1 206ASD142 206ASD142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 SCREW–TAPPING 1 75LM72 75LM72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 NUT–FLANGED 1 50AW4 50AW4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 SCREW–SELF TAPPING 1 75K75 75K75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 GRILL 1 202ASD736 202ASD736. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 SCREW–TAPPING 8 75LM72 75LM72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 CLIP–U/NUT 8 31D57 31D57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 SCREW–FLANGED HD 4 75LM78 75LM78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 NUT–FLANGED 4 50AW5 50AW5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 WASHER–PLAIN 8 95A3C 95A3C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 STRAP–ADJUSTMENT ENGINE BELT 1 200ASD228 200ASD228. . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 CLAMP–MOTOR ADJUSTMENT 1 200ASL654 200ASL654. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 SCREW–HEX 1/2–13X6 1 75AA101C 75AA101C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 WASHER–PLAIN 1 95F5C 95F5C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 RECEIVER–AIR 1 207ASD645 205ASD645. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 COCK See ( ) 90C12 (2) 90C12 (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 NIPPLE–PIPE (10 GALLON TWIN–TANK UNIT ONLY) 1 63F21G NONE. . . . . . . . . . . . . . 353 GAUGE (30 GALLON UNIT ONLY) 1 NONE 27P201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 TEE 1 64P7G NONE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 ELBOW 2 64D2G NONE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 GAUGE 1 27P201 NONE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 TEE–PIPE 1 64T38G NONE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 VALVE–PRESSURE RELIEF 1 90AR734 90AR734. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362 ELBOW 1 64C2G 64C2G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 NIPPLE PIPE 1 63D38G 63D23G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 CAP–PIPE 1 64AD2G 64AD2G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 NIPPLE PIPE 1 63D3G 63D3G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 NIPPLE PIPE (KOHLER ENGINE ONLY) 1 63F4G 63F4G. . . . . . . . . . . . . . . . . . . . . . . . . . 405 NIPPLE PIPE 1/4X4 (HONDA ENGINE ONLY) 1 200ASD126 200ASD126. . . . . . . . . . . . . . . . . . . . . 406 CAP–PIPE (KOHLER ENGINE ONLY) 1 64AD4G 64AD4G. . . . . . . . . . . . . . . . . . . . . . . . . . . . 406 CAP–PIPE (HONDA ENGINE ONLY) 1 64AD2G 64AD2G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702 SUCTION FILTER (Includes Reference Number 703) 1 5L175 5L175 . . . . . . . . . . . . . . . 703 REPLACEMENT ELEMENT 1 2109945 2109945. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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200ARD810(Ref. Drawing)

DRIVE MOUNTING & ENGINE GROUP


KOHLER ENGINE

1 SHEAVE 1 73S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 BELT 1 13E504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 BOLT STEP CARRIAGE 4 15AA7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 NUT–FLANGED 4 50AW5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* KOHLER ENGINE 1 200ASD278. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HONDA ENGINE

1 SHEAVE 1 73S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 BELT 1 13E504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 BOLT–STEP CARRIAGE 4 15AA5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 NUT–FLANGED 4 50AW5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* HONDA ENGINE 1 201ASD278. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* ENGINE MOUNTING PLATE 1 201ASD247. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* SCREW–HEX HD 4 655ED06Z. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* WASHER–PLAIN 4 95F3C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* Not Shown on Drawing

NOTE: INSTALLATION AND PERFORMANCE OF ENGINES OTHER THAN THOSE LISTED ABOVEARE NOT GUARANTEED BY GARDNER DENVER.

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CONTROL GROUP


501 PILOT–UNLOADER 1 90AR955 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

502 VALVE–PRESSURE RELIEF 1 90AR735 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

503 NIPPLE PIPE GALVANIZED 1 63D3G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

504 COUPLING PIPE 1 64BK2G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

505 THROTTLE VALVE 1 90AR961. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

511 NIPPLE–PIPE (TEN GALLON TWIN–RECEIVER) 1 63F21G. . . . . . . . . . . . . . . . . . . . . .

511 NIPPLE–PIPE (30 GALLON RECEIVER) 1 63F4G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

512 ELBOW–PIPE ST (30 GALLON RECEIVER ONLY) 1 64D1G. . . . . . . . . . . . . . . . . . . . .

601 ELBOW–TUBE 2 86A116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 TUBE 3 85D10C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PISTON RING ARRANGEMENT

SPARE PARTS – REPAIR KITS

PISTON RING KIT (Includes Low Pressure & High Pressure Piston Rings) ASK80827. . . . . . . . . . . . . . . . . . . LOW PRESSURE VALVE KIT (Includes (1) Valve & (2) Gaskets) 200ASD6017. . . . . . . . . . . . . . . . . . . . . . . . . . . . HIGH PRESSURE VALVE KIT (Includes (1) Valve & (2) Gaskets) 201ASD6017. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER KIT 202ASD6002. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCLUDES:(1) CRANKCASE/CYLINDER 203ASD013. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) GASKET KIT 200ASD6007. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKET KIT 200ASD6007. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCLUDES:(1) SEAL–OIL 60G114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) SHIM 200ASD732. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) O–RING 25AM18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) GASKET–OIL PAN 206ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) GASKET 202ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) GASKET 203ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) GASKET 204ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) GASKET 205ASD715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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STANDARD DIMENSIONS & RUNNING CLEARANCES

UNIT COLD(New Parts)

Compressor LP HP

Cylinder Bore 4.750/4.751 2.500/2.501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Ring Land Diameter 4.722/4.717 2.481/2.476. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston to Cylinder (At Ring Land) .028/.034 .019/.025. . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Skirt Diameter 4.7405/4.7395 2.4990/2.4985. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston to Cylinder (At Skirt) .0095/.0115 .0010/.0025. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ring Gap – Compression. .005/.015 .003/.013. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ring Side Clearance (Compression) .002/.004 .002/.004. . . . . . . . . . . . . . . . . . . . . . . .

Rail Ring Gap – Oil .010/.050 .015/.055. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pin Bore in Piston .8755/.8760 .8755/.8760. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pin to Connecting Rod. .0008/.0015 .0008/.0015. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pin to Piston. .0003/.0010 .0003/.0010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pin Diameter .8752/.8750 .8752/.8750. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pin Bore in Connecting Rod .8760/.8765 .8760/.8765. . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod Crankpin Insert Bore 1.6240/1.624 1.6240/1.624. . . . . . . . . . . . . . . . . . . . . . .

Insert to Crankpin .0005/.0020. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Crankpin Diameter 1.4990/1.4985. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod Side Clearance. .014/.031. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Diameter (At Main Bearing) 1.2525/1.2515. . . . . . . . . . . . . . . . . . . . . .

Housing Bore (Main Bearing) 2.3255/2.3260. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing ID . 1.2500/1.2505. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing OD . 2.3290/2.3280. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing End Clearance. .0005/.0015. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE DATA (DRY)(Foot–Pounds)

Connecting Rod Bolts. 13–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase End Plate Bolts 16–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Bolts, LP 29–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Bolts, HP 29–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pan Bolts 29–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Nut 75–85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve to Head 12–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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FOREWORD

Gardner Denver compressors are the result of advanced engineering and skilled manufacturing. To be assured ofreceiving maximum service from this machine the owner must exercise care in its operation and maintenance. Thisbook is written to give the operator and maintenance department essential information for day–to–day operation,maintenance and adjustment. Careful adherence to these instructions will result in economical operation and mini-mum downtime.

Danger is used to indicate the presence of a hazard which will cause severe personalinjury, death, or substantial property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe person-al injury, death, or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minorpersonal injury or property damage if the warning is ignored.

Notice is used to notify people of installation, operation or maintenance informationwhich is important but not hazard–related.

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SAFETY PRECAUTIONS

Safety is everybody’s business and is based on your use of good common sense. All situations or circumstancescannot always be predicted and covered by established rules. Therefore, use your past experience, watch out forsafety hazards and be cautious.

Some general safety precautions are given below:

Failure to observe these notices could result in injury to or death of personnel.

� Do not operate unit if safety devices are not operating properly. Check period-ically. Never bypass safety devices.

� Keep fingers and clothing away from revolving fan, belts and sheaves.

� Do not use the air discharge from this unit for breathing – not suitable for hu-man consumption.

� Do not loosen or remove the oil filler plug, drain plugs, covers, or break anyconnections, etc., in the compressor air or oil system until the unit is shutdown and the air pressure has been relieved.

� Electrical shock will result in injury or death to personnel. Open main discon-nect switch before working on the control.

� Compressor unit must be grounded in accordance with the National ElectricalCode.

� Disconnect the compressor unit from its power source, tag and lockout be-fore working on the unit – this machine is automatically controlled and maystart at any time.

� Do not modify unit without written permission from Manufacturer’s Engineer-ing Department.

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Failure to observe these notices could result in damage to equipment.

� Stop the unit if any repairs or adjustments on or around the compressor arerequired.

� An Excess Flow Valve should be on all compressed air supply hoses ex-ceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)

� Do not exceed the rated maximum pressure values shown on the nameplate.

� Bearings can be damaged by passage of current. Do not electric weld on thecompressor or base.

� Inspect the air receiver for fatigue cracks and inspect all pipe and tube con-nections for looseness or leakage on at least an annual basis.

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INSTALLATION AND OPERATING INSTRUCTIONS

The Installation and Operating Instructions should beread carefully before starting the unit.

LOCATION – The compressor should be installed in aclean, well–lighted place, with plenty of space aroundit, and in such a manner as to be accessible from allsides. Do not place unit too near other machinery or tooclose to the wall. Unit should be set on a firm founda-tion, with the feet shimmed to eliminate rocking and un-due stresses when bolted to the foundation.

PIPING – Air discharge pipe must be full size of dis-charge opening on air cylinder. The discharge pipeshould be as short and direct as possible, eliminatingshort bends and fittings and avoiding pockets. If for anyreason it is necessary to install a gate or globe valve be-tween compressor and receiver, it is imperative that apressure relief valve be placed in the line between thecompressor and the valve.

Do not operate the compressor with-out the proper pressure relief valve.Overpressure operation may causesevere damage to equipment and per-sonal injury.

As the air cools in being carried through the distributinglines to the point at which it is to be used, it depositsmoisture mixed with a small amount of oil. This mois-ture is objectionable in pneumatic tools, sand blasting,paint spray work and similar operations. Much of thetrouble with water in the air lines can be overcome ifsmall receivers to act as collecting tanks are put in thelines at frequent intervals, otherwise suitable moisturetraps should be used.

All pressure relief valves should betested daily by hand to be sure thatthey are functioning properly. Failureto perform test daily could result inpersonal injury or damage to equip-ment.

LUBRICATING SYSTEM – All ASD models are splashlubricated.

“V” BELT DRIVE – The “V” belt drive consists of a rub-ber–fabric composition belt operating in a groovedpulley. An adjustable motor base is provided to take upstretch of belts. The belts should be run only fairly tight.No belt dressing of any sort is required. Always installa new belt when belt becomes worn.

COVERS AND GUARDS

All compressor covers and guardsmust be securely fastened in properposition at all times when the com-pressor is operating to avoid person-al injury or death from moving parts.In addition, all moving parts on theentire compressor package, includ-ing but not limited to engine or mo-tors, drive shafts, belts, pulleys, etc.,must be equipped with guards or cov-ers, which must also be securely fas-tened in the proper position at alltimes when equipment is operating.Covers and guards are intended tonot only protect against personal in-jury or death, but to also protect theequipment from damage from foreignobjects.

AIR FILTER – The intake of every compressor must beequipped with an air filter to prevent dust and otherabrasives from being drawn into the cylinders.

In cases where no air filter is installed, the company willassume no responsibility for excessive wear of pistons,piston rings, cylinder bore or valve details, even thoughsuch wear occurs very soon after compressor isinstalled. To operate properly, the filters must be keptclean.

Maintain the engine air filter per instruction in the en-gine manufacturer’s manual.

PRESTART CHECK – Before starting the unit for thefirst time, be certain that all the accessory items

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shipped loose with the unit are properly installed; i.e.,compressor air filter, pressure relief valve, etc.

Check over the electrical connections to see that allconnections are tight and properly made before start-ing the engine.

Go over all bolts, nuts, and valve clamp screws to seethat they are tight.

Service the engine per instructions in the enginemanufacturer’s manual.

Break–in oil is supplied in thecrankcase from the factory. Changeoil after 50 hours and refill the crank-case with lubricating oil. See Lubrica-tion section below.

INITIAL STARTING – When starting for the first time,be certain that all items in the prestart check have beencomplied with.

On initial start or after the compressor has been over-hauled, run the compressor with the receiver outletvalves wide open for about ten minutes so that oil will

be distributed over all wearing surfaces. When surethat the unit is operating satisfactorily, partly close thereceiver valve and gradually bring the pressure up tonormal working pressure.

LUBRICATION – Oil level in the crankcase must bemaintained. Add oil as required to maintain the correctlevel. The viscosity required for various operating tem-perature ranges is listed in the Viscosity Chart,FIGURE 1, below.

Correct weight of oil for existing temperatures is mostimportant. Oil which is too heavy cannot be picked upby the oil pump or splash freely and will cause bearingdamage and subsequent failure.

Approximately 2.6 quarts of oil are required to fill thecrankcase.

The oil level must be checked and maintained on a dailybasis.

Maintain engine oil per instructions in the enginemanufacturer’s manual.

OIL QUALITY – There are many brands of lubricatingoils which are represented by the suppliers as meetingthe specifications for vertical compressor lubrication.The ability of an oil to meet the minimum performancelevel for a particular application is determined by thesupplier. Therefore, the responsibility for the QUALITYof the oil and its PERFORMANCE IN SERVICERESTS WITH THE OIL SUPPLIER.

Cold Weather Operation: 0� F. to 32� F. Ambient –

Reciprocating Compressor Oil ISO Viscosity Grade 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm Weather Operation: 32� F. to 90� F. Ambient –

Gardner Denver AEON 500 Lubricant ISO Viscosity Grade 68*. . . . . . . . . . . . . . . . . . . . . . . . . .

Warm Weather Operation: Above 90� F. Ambient –

Gardner Denver AEON 500 Lubricant ISO Viscosity Grade 100**. . . . . . . . . . . . . . . . . . . . . . . .

* AEON 500 (SAE20) available in 6 pack of 1 Gallon Containers – Part Number 28H60or 5 Gallon Pail – Part Number 28H58or 55 Gallon Drum – Part Number 28G12

** AEON 500 (SAE30) available in 6 pack of 1 Gallon Containers – Part Number 28G22or 5 Gallon Pail – Part Number 28G19or 55 Gallon Drum – Part Number 28G13

FIGURE 1 – VISCOSITY CHART

1–1–550 Page 19

Mixing of different types or the use ofinferior lubricants will result in theformation of heavy varnish andsludge throughout the compressor.

OIL CHANGE – When a new or overhauled unit isplaced in service, the oil should be changed at the endof the first 50 hours of operation. The oil should bechanged again after the next 100 hours operation sothat all polishing residue from working parts will be re-moved from the crankcase.

Subsequent oil change periods must be determined bychecking the discoloration and physical condition of theoil in the crankcase. Due to dust, dirt and atmosphericconditions being different at various locations, it is notpractical to definitely state how often the lubricating oilin the crankcase should be changed. Service given theair filter and crankcase breather also has a direct bear-ing on the oil change interval, as does high humidityconditions which contribute to formation of varnish de-posits through oxidation of the oil. The period forchanging oil is therefore regulated by local conditions.The oil, however, should not be used for more than 500hours.

Always provide clean containers, funnels and cleanstorage of oil and cleaning fluids. Changing oil will beof little benefit if done improperly.

Fill the crankcase through the opening. Check the levelwith the dipstick. Wipe away all dirt before removing theoil filler plug. After the unit has operated for severalminutes, check the oil level and add if necessary.

When starting the unit after an oil change, start slowlyunder no–load until assured the oil reaches all movingparts.

Condensate accumulation in the crankcase will oftenoccur as a result of high humidity conditions, wide tem-perature range and intermittent service.

DUTY CYCLE – All units operating at 175 PSIG or lessare rated for continuous operation in an ambient tem-perature of 104� F. or less.

Operation above 104� F. is not recommended.

MAIN BEARING ADJUSTMENT – Main bearings aretapered roller type and seldom require adjustment.

They are correctly adjusted at the factory by means ofthin shims under the bearing end plate. Should adjust-ment become necessary, both bearings are adjustedsimultaneously by removing the required number ofshims from beneath the end plate opposite the driveend. This adjustment must be made with care so thatbearings will not be too tight.

Before and during maintenance workbe absolutely sure these rules arefollowed:

A. Remove the ignition key from theengine and disconnect the bat-tery cables, if used.

B. Pressure in the air system iscompletely released.

C. Never reach hand into crankcasewithout being conscious of thefact that the crankshaft can rotatedue to the position of the counter-weights.

D. Proper equipment and tools areused.

Failure to observe these precautionswill result in injury or death.

CRANKPIN BEARINGS – Crankpin bearings are ofthe renewable insert type. When installing new inserts,the bore of the rod and the back of the insert must beabsolutely free of dirt and burrs. Dirt or burrs under theinsert will cause early insert failure.

Where there is a possibility of bearing metal or dirt en-tering the oil passages of the conn–rod, the passagesmust be thoroughly cleaned before installing new in-serts. Coat the crankpin with oil to prevent a dry start.The small projection on the insert must fit in the corre-sponding recess in the rod and cap. Do not file the endsof the inserts or rod caps.

Assemble the rod and cap with the index tabs on thesame side. Tighten the bolts evenly until proper torqueis attained.

1–1–550 Page 20

Do not pull up each bolt to ratingseparately as this will cause the rodbore to deform to an out–of–roundcondition.

CRANKSHAFT OIL SEAL must be installed with thelips of the seal facing in toward the oil side to retain oilin crankcase.

VALVES – It is advisable to have spare valve assem-blies on hand for replacement when required.

Never run the compressor with avalve that does not operate properlyas a leaky valve will cause excessivetemperatures and may cause anexplosion in the air receiver ordischarge line.

CONTROL SYSTEM – The compressor operatingpressure is controlled by a pneumatic pilot that is presetat the factory. In the event that adjustment is required,follow these instructions:

UNLOADER PILOT – (See FIGURE 2)

Unloading Pressure (Cut–Out 125 to 175 PSIG):

1. Loosen jam nut “B”.

2. Turn “A” clockwise to increase or counterclock-wise to decrease pressure.

3. Tighten jam nut “B”.

Differential Pressure (Cut–In PSIG):

1. Hold jam nut “D” so it does not move.

2. Turn “C” very slightly clockwise to increase orcounterclockwise to decrease pressure.

The differential adjustment range issmall. Attempting to adjust thisbeyond the designed range will resultin unstable operation of the pilot.

A

B

C

D

FIGURE 2 – UNLOADER PILOT ILLUSTRATION

WARRANTYGARDNER DENVER

RECIPROCATING COMPRESSORS

BB–58 R 9/95

Gardner Denver AVS Parts List & Service Manual

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