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R-SERIES
Air Compressors and Units

OPERATION & SERVICE MANUAL

Electric Drive Compressors & Units

R-10/15 R-30 R-40 R-70

THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD ALWAYS

BE AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT. READ, UNDERSTAND
AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT TO PREVENT
INJURY OR EQUIPMENT DAMAGE.

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MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH

GENUINE CHAMPION® COMPRESSOR
PARTS AND SUPPORT SERVICES

Champion® Compressor genuine parts, manufactured to design tolerances, are developed for
optimum dependability – specifically for Champion compressor systems. Design and material
innovations are the result of years of experience with hundreds of different compressor
applications. Reliability in materials and quality assurance are incorporated in our genuine
replacement parts.

Your authorized Champion Compressor distributor offers all the backup you’ll need. A
worldwide network of authorized distributors provides the finest product support in the air
compressor industry. Your authorized distributor can support your Champion air compressor
with these services:

1. Trained parts specialists to assist you in selecting the correct replacement parts.

2. A full line of factory tested CHAMPLUB™ compressor lubricants specifically formulated

for use in Champion compressors.

3. Repair and maintenance kits designed with the necessary parts to simplify servicing your
compressor.

Authorized distributor service technicians are factory trained and skilled in compressor
maintenance and repair. They are ready to respond and assist you by providing fast, expert
maintenance and repair services.

To Contact Champion or locate your local distributor:

Visit: www.championpneumatic.com

Or

Call: (888)436-5499

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Compressor MODEL, HORSEPOWER and SERIAL NUMBER
(see nameplate on unit). All orders for Parts should be placed with the nearest authorized
distributor.

Order by part number and description. Reference numbers are for your convenience only.

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Table of Contents
Safety and Operation Precautions ................................................................................................................ 5

Explanation of Safety Instructions, Symbols, and Decals ............................................................................. 6

Safety and Operation Precautions ................................................................................................................ 6

Unit Hazard Decal List – See Page 8 .............................................................................................................. 7

Pump Hazard Decal List – See Page 9 ........................................................................................................... 7

Unit Hazard Decals ........................................................................................................................................ 8

Pump Hazard Decals ..................................................................................................................................... 9

Installation .................................................................................................................................................. 10

Air Receiver Installation .............................................................................................................................. 13

Operation .................................................................................................................................................... 14

Low Oil Shutdown Control .......................................................................................................................... 16

Compressor Oil Specifications .................................................................................................................... 18

Guide to Maintenance ................................................................................................................................ 20

Maintenance Checklist ................................................................................................................................ 26

Troubleshooting Chart ................................................................................................................................ 27

Maintenance Log ........................................................................................................................................ 29

Maintenance Log ........................................................................................................................................ 30

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Safety and Operation Precautions

Because an air compressor is a piece of machinery with moving and rotating parts, the same precautions should be
observed as with any piece of machinery of this type where carelessness in operation or maintenance is hazardous
to personnel. In addition to the many obvious safety rules that should be followed with this type of machinery, the
additional safety precautions as listed below must be observed:

1. Read all instructions completely before operating air compressor or unit.

2. For installation, follow all local electrical and safety codes, as well as the National Electrical Code (NEC) and
the Occupational Safety and Health Act (OSHA).
3. Electric motors must be securely and adequately grounded. This can be accomplished by wiring with a
grounded, metal-clad raceway system to the starter; by using a separate ground wire connected to the bare
metal of the motor frame or other suitable means.
4. Protect the power cable from coming in contact with sharp objects. Do not kink power cable and never allow
the cable to come in contact with oil, grease, hot surfaces, or chemicals.
5. Make certain that the power source conforms to the requirements of your equipment.
6. Pull main electrical disconnect switch and disconnect any separate control lines, if used, before attempting to
work or perform maintenance on the air compressor or unit. "Lock out" or "Tag out" all power sources.
7. Do not attempt to remove any compressor parts without first relieving the entire system of pressure.
8. Do not attempt to service any part while machine is in an operational mode.
9. Do not operate the compressor at pressures in excess of its rating.
10. Do not operate compressor at speeds in excess of its rating.
11. Periodically check all safety devices for proper operation. Do not change pressure setting or restrict
operation in any way.
12. Be sure no tools, rags, or loose parts are left on the compressor or drive parts.
13. Do not use flammable solvents for cleaning the air inlet filter or element and other parts.
14. Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts by covering
parts and exposed openings with clean cloth or Kraft paper.
15. Do not operate the compressor without guards, shields and screens in place.
16. Do not install a shut-off valve in the discharge line, unless a pressure relief valve, of proper design and size, is
installed in the line between the compressor unit and shut-off valve.
17. Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic fumes.
18. Be careful when touching the exterior of a recently run motor - it may be hot enough to be painful or cause
injury. With modern motors this condition is normal if operated at rated load - modern motors are built to
operate at higher temperatures.
19. Inspect unit daily to observe and correct any unsafe operating conditions found.
20. Do not "play around" with compressed air nor direct air stream at body. This can cause injuries.
21. Compressed air from this machine absolutely must not be used for food processing or breathing air without
adequate downstream filters, purifiers and controls.
22. Always use an air pressure regulating device at the point of use. Do not use air pressure greater than marked
maximum pressure of attachment.
23. Check hoses for weak or worn condition before each use and make certain that all connections are secure.
24. Always wear safety glasses when using compressed air gun.

The user of any air compressor package manufactured by Champion – A Gardner Denver Co., is hereby warned
that failure to follow the preceding Safety and Operation Precautions can result in injuries or equipment damage.
However, Champion – A Gardner Denver Co., does not state as fact or does not mean to imply that the preceding
list of Safety and Operating Precautions is all inclusive, and further that the observance of this list will prevent all
injuries or equipment damage.

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Explanation of Safety Instructions, Symbols, and Decals

Indicates immediate hazards which will result in severe injury or death.

Indicates hazards or unsafe practice which could result in severe injury or death.

Indicates hazards or unsafe practice which could result in damage to the Champion compressor or
minor injury.

NOTICE
Notice is used to notify people of installation, operation, or maintenance information which is
important but not hazard related.

Safety and Operation Precautions

OBSERVE, UNDERSTAND, AND RETAIN THE INFORMATION GIVEN IN THE SAFETY PRECAUTION
DECALS AS SHOWN IN THE DECAL LIST SECTION.

This Oil-Lubricated Compressor must not be used for breathing air without adequate downstream
filters, purifiers, and controls. To do so will cause serious injury whether air is supplied direct from
the compressor source or to breathing tanks for later use. Any and all liabilities for damage or loss
due to injuries, death and/or property damage including consequential damages stemming from
the use of this compressor to supply breathing air will be disclaimed by the manufacturer.

The use of this compressor as a booster pump and/or to compress a medium other than
atmospheric air is strictly non-approved and can result in equipment damage and/or injury. Non-
approved uses will also void warranty.

This unit may be equipped with special options which may not be included in this manual. User
must read, understand, and retain all information sent with special options.

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Unit Hazard Decal List – See Page 8

PART NO. DESCRIPTION
P10157A PRODUCT LIABILITY DECAL SHEET - MASTER
1 Unit Pressure Setting
2 NOT USED
3 DANGER – Breathing Air
4 DANGER – Drain Tank Daily
5 WARNING – Pressure/Safety Valve
6 NOT USED
7 DANGER – Valve Maintenance
8 DANGER – High Voltage
9 WARNING – Hot Surfaces
10 WARNING – Do Not Remove Fan Guard
11a NOTICE - Lubricant
11b NOT USED
12 DECAL – Synthetic or Food Grade Inserts
13 NOT USED
14 DECAL – Pressure Setting: 95-125 PSIG
14 DECAL – Pressure Setting: 140-175 PSIG
15 NOTICE – Read and Retain Manuals
16 NOT USED
17 DECAL – Rotation Direction
18 NOT USED
P14677A DECAL – Pressure Switch

Pump Hazard Decal List – See Page 9

PART NO. DESCRIPTION
P13805A PUMP DECAL SHEET – MASTER
A1 NOT USED
A2 NOTICE - Lubricants
B DECAL – Rotation Direction
C NOTICE – Read and Retain Manuals
D DANGER – Breathing Air
E DECAL – Made in the United States of America
F IMPORTANT NOTICE – Motor Burn-Outs

P14677A

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Unit Hazard Decals

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Pump Hazard Decals

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Installation

Do not operate unit if damaged during shipping, handling or use. Operating unit if damaged may
result in injury.

1. Permanently installed compressors must be located in a clean, well ventilated dry room so
compressor receives adequate supply of fresh, clean, cool, and dry air. It is recommended that a
compressor, used for painting, be located in a separate room from that area wherein body sanding
and painting is done. Abrasive particles or paint, found to have clogged the air intake filters and
intake valves, shall automatically void warranty.
2. Compressors should never be located so close to a wall or other obstruction that flow of air through
the fan-bladed flywheel, which cools the compressor, is impeded. Permanently mounted units
should be installed so that the belt guard is at least 12" from wall.
3. Place stationary compressors on firm level ground or flooring. Permanent installations are required
to be anchored to floor. Bolt holes are provided in the air receiver or base feet. Use shims to level
the compressor unit. It is recommended that optional vibration isolator pads be installed with the
unit. Tanks anchored directly to a concrete floor without vibration isolator pads will not be
warranted against cracking. Champion vibration isolator pads must be used for extended warranty
to apply to ASME air receivers. See “Air Receiver Installation” section.

Do not tighten the anchor screws/nuts down completely – this will result in undesirable stress on
the tank foot. This can cause abnormal vibration and possible cracking of the air receiver, resulting
in injury or equipment damage.

4. If installing a bare pump or a base-mounted unit, make certain the system has adequate pressure
limiting controls. Controls could be a pressure switch for start/stop operation or a pilot valve for
continuous operation. If a pilot valve is used, the compressor must be equipped with head
unloaders. Control air must be piped from the air receiver to the pilot valve.
5. A properly sized air check valve must be installed in the discharge piping, between the compressor
outlet and the inlet of any receiver tank(s) in the system.

Do not install isolating valves between compressor outlet and air receiver. This will cause excessive
pressure if valve is closed, and cause injury and equipment damage.

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Installation (continued)

Always use an air pressure regulating device at the point of use. Failure to do so can result in injury
or equipment damage.

● Do not install in an area where ambient temperature is below 32°F or above 104°F.
● Do not install unit in an area where air is dirty and/or chemical laden.
● Unit is not to be installed outdoors.

ELECTRICAL POWER SUPPLY

It is essential that the power supply and the supply wiring are adequately sized and that the voltage
corresponds to the unit specifications. Branch circuit protection must be provided at installation as
specified in the National Electrical Code.

All wiring should be performed by a licensed electrician or electrical contractor. Wiring must meet
applicable codes for area of installation. The table gives recommended wire sizes based on the 2017
NEC.

WIRE SIZE (AWG) - 75°C COPPER - 40°C AMBIENT

MOTOR 3 PHASE 1 PHASE
HP 200/208V 230V 460V 575V 115V 208V 230V
2 14 (12) 14 (12) 14 (14) 14 (14) 8 (4) 12 (8) 12 (10)
3 12 (10) 14 (10) 14 (14) 14 (14) 6 (3) 10 (6) 10 (8)
5 10 (6) 12 (8) 14 (12) 14 (12) -- 8 (4) 8 (4)
7-1/2 8 (4) 10 (6) 14 (10) 14 (10) -- 4 (1) 6 (2)
10 8 (3) 8 (4) 12 (8) 14 (10) -- -- --
15 4 (1) 6 (2) 10 (6) 10 (6) -- -- --
20 3 (00) 4 (0) 8 (4) 10 (6) -- -- --
25 1 (0000) 2 (000) 6 (3) 8 (4) -- -- --
30 0 (250) 1 (0000) 6 (2) 8 (4) -- -- --

Values in ( ) for Duplex Unit w/one incoming power line to both motors.

All models require a properly sized magnetic starter as specified in the National Electric Code (NEC).
See Control Panel Manual for details.

If ordered with a factory mounted control panel, compressor is wired at factory. It is necessary only to
bring lines from a properly sized disconnect switch to the control panel mounted on the unit.

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Installation (continued)

Wiring must be such that when viewing compressor from opposite shaft end, rotation of shaft is
clockwise as shown by arrow on guard. Wrong direction rotation for any length of time will result
in damage to compressor.

GROUNDING INSTRUCTIONS

This product should be connected to a grounded, metallic, permanent wiring system, or an equipment-
grounding terminal or lead on the product.

AIR LINE PIPING

Connection to air system should be of the same size, or larger, than discharge pipe out of unit. The table
gives recommended minimum pipe sizes. A union connection to the unit and water drop leg is
recommended. Install a flexible connector between the discharge of the unit and the plant air piping.
Plant air piping should be periodically inspected for leaks using a soap and water solution for detection
on all pipe joints. Air leaks waste energy and are expensive.

Minimum Pipe Sizes For Compressor Air Lines

(Based on clean Smooth Schedule 40 Pipe)

MODEL 25’ 50’ 100’ 200’ 300’

R10D 3/4” (1”) 3/4” (1”) 3/4” (1”) 3/4” (1”) 3/4” (1”)
R15B 3/4” (1”) 3/4” (1”) 3/4” (1”) 1” (1-1/4”) 1” (1-1/4”)
R30D 3/4” (1-1/4”) 1” (1-1/4”) 1” (1-1/4”) 1” (1-1/2”) 1” (1-1/2”)
R40A 1-1/4” (1-1/2”) 1-1/4” (1-1/2”) 1-1/4” (1-1/2”) 1-1/4 (1-1/2”) 1-1/4” (1-1/2”)
R70A 1-1/4” (1-1/2”) 1-1/4” (1-1/2”) 1-1/4” (1-1/2”) 1-1/2” (2”) 1-1/2” (2”)

Values in ( ) are for duplex unit.

Never use plastic pipe or improperly rated metal pipe. Improper piping material can burst and cause
injury or property damage.

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Air Receiver Installation

Vibration isolator pads can be purchased from your local authorized distributor. Installation hardware
items (studs, screws, nuts, shims) are not provided. It is the compressor owner’s responsibility to
provide a suitable foundation and isolator installation.

Do not tighten the anchor screws/nuts down completely – this will result in undesirable stress on
the tank foot. This can cause abnormal vibration and possible cracking of the air receiver, resulting
in injury or equipment damage.

CUT-AWAY VIEW OF
TEN011442-01 ANCHORED
(Ref. Drawing) INSTALLATION

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Operation
This compressor has been inspected, thoroughly tested and approved at the factory. For this unit to
give long satisfactory service it must be installed and operated properly. This compressor has been
designed for an 80%/ON – 20%/OFF duty cycle.

SIMPLEX UNITS have a pressure switch that senses changes in receiver pressure and automatically starts
and stops the compressor at preset pressure limits. If the receiver pressure falls below the cut-in
pressure setting of the pressure switch the compressor will run until the cut-out pressure setting of the
pressure switch has been reached.

DUPLEX UNITS have lead (PS1) and lag (PS2) pressure switches and an automatic alternating system to
evenly distribute the load between the two compressors. The pressure switches sense changes in
receiver pressure and automatically start and stop the compressor at preset pressure levels. If the
receiver pressure falls below the cut-in pressure setting of the lead (PS1) pressure switch but remains
above the cut-in pressure setting of the lag (PS2) pressure switch, only one compressor will run until
receiver pressure reaches the cut-out pressure of the lead (PS1) pressure switch. The next time the
pressure in the receiver drops, the system automatically starts the compressor that was idle. If the
receiver pressure falls below the cut-in pressure setting of the lag (PS2) pressure switch, both
compressors run until receiver pressure reaches the cut-out pressure setting of the lead (PS1) pressure
switch.

CONTINUOUS RUN units are equipped with a ball valve, pilot valve and head unloaders to provide
continuous run capabilities. The pilot valve acts as an automatic air switch allowing air to flow from the
receiver to the head unloader mechanism, thus actuating it. To operate unit in continuous run, open
ball valve located next to pilot valve. The pilot valve is now able to sense receiver pressure. When the
receiver pressure reaches the cut-out pressure setting of the pilot valve, the pilot valve opens and air is
released to the unloader mechanism. The compressor stops compressing air and runs unloaded until
the cut-in pressure setting of the pilot valve has been reached. At this time air released from the
unloader mechanism and the compressor starts compressing again. Continuous run is recommended if
motor starts exceed 8 starts/hour.

INITIAL START UP – ELECTRIC MOTOR UNITS

1. Inspect unit for any visible signs of damage that would have occurred in shipment or during
installation.

2. Pull main disconnect switch to unit to assure that no power is coming into the unit. “Lock Out” or
“Tag Out” switch. Connect power leads to start.

Do not attempt to operate compressor on voltage other than that specified on order or on
compressor motor and control panel. Voltage conversion kits are available if alternate operating
voltage is required.

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Operation (continued)

3. Check compressor oil level. Add oil as required. See “Compressor Oil Specifications” Section.
NOTE: Do not mix oil type, weights, or brands.

4. Activate main disconnect switch.

5. “Jog” motor and check for proper rotation by direction arrow. If rotation is wrong, reverse input
connections on the magnetic starter.

6. Close receiver discharge ball valve and start the compressor.

7. With receiver ball valve closed, let the machine pump up to operating pressure.

8. Check for proper operation of the pressure switch.

a. When the air receiver pressure reaches the cut-out setting of the pressure switch, the
machine will stop.
b. Open the receiver ball valve slowly, allowing pressure in the receiver to drop.
c. When the air receiver pressure drops to the cut-in setting of the pressure switch, the
machine will start.
d. Repeat steps a. thru c. three times.

9. Check for proper operation of the head unloaders (if equipped).

a. Open the ball valve located next to the pilot valve.
b. When the air receiver pressure reaches the cut-in setting of the pilot valve, the head
unloaders will activate. The air compressor continues to run, but air compression is stopped.
c. Open the receiver ball valve slowly, allowing pressure in the receiver to drop.
d. When the air receiver pressure drops to the cut-out setting of the pilot valve, the head
unloaders will de-activate. Air compression will resume.
e. Repeat steps b. thru d. three times.

10. Check for proper operation of any options.

11. When the initial run period has shown no operating problems, shut unit down and recheck oil level.

12. Open receiver ball valve. The air compressor unit is now ready for use.

This unit can start automatically without warning.

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Low Oil Shutdown Control

(optional equipment)

The oil monitor must be used in conjunction with a magnetic starter (see wiring diagram for details).
The oil monitor is installed on the outside of the air compressor crankcase with a port that allows oil
to feed into it’s float bowl chamber and maintain the same level as in the crankcase. The float moves
vertically up or down as the oil level changes. If the oil level is below minimum allowable operating
level, the reed switch will open, thus stopping the motor. A magnet holds the float and prevents the
compressor from starting. In order to start the compressor the following steps must be taken:

1. Fill crankcase to recommended capacity as indicated when level reaches the middle of the oil
sight glass.
2. Turn cam reset knob 90° clockwise.

IMPORTANT NOTE: The Oil Monitor does not eliminate the compressor owner's responsibility for
periodically checking oil level. Refer to maintenance instructions.

C509-A
(Ref. Drawing)

WIRING DIAGRAM: Refer to the Control Panel User Manual for complete wiring diagrams.

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Low Oil Shutdown Control (continued)

(optional equipment)

TROUBLESHOOTING & SERVICING

Always disconnect unit from power supply and relieve all pressure from air tank before
performing any maintenance. “Lock Out” or “Tag Out” all power sources. Failure to do so
may result in personal injury or death.

NOTICE
Do not disassemble LOSC switch. Disassembly will void warranty.

No adjustments are required for the oil monitor.

If the oil monitor does not operate properly, check the items listed below to determine the cause.

1. Crankcase Oil

a. Check sight glass to insure proper oil level in crankcase, when compressor is shut off.
b. Check crankcase oil for proper viscosity. This is particularly important for temperature
conditions below 32˚F. Oil which is too thick can slow the response of the mechanism,
causing float to register a low level.
c. Change oil regularly. Clean oil insures proper operation of the Oil Monitor, as well as
compressor. See Compressor Oil Specification and Maintenance sections for details.

2. Vent Tube

a. Check vent tube to insure it is not clogged.

b. Check the gasket between valve body and bowl for leaks. This will cause a pressure rise in
the crankcase which will give a false safe oil level indication.
c. Check the fittings at ends of vent tube for tightness and leaks.

3. Reset
a. Check that reset return spring is in proper working order.
b. Verify that reset knob is in fully counterclockwise position.

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Compressor Oil Specifications

Compressors are factory filled with CHAMPLUB hydrocarbon-based recip lubricant. This is an ISO 100
non-detergent industrial lubricant with rust and oxidation inhibitors specially formulated for
reciprocating compressors. It is recommended this compressor be maintained using this oil for ambient
temperatures above 32°F.

CHAMPLUB synthetic is a premium grade diester based synthetic lubricant providing excellent
performance in high temperature applications.

Do not mix oil types, weights or brands.

Emulsification of oil (white milky substance) indicates unsafe accumulation of moisture and may
be evidence compressor is oversized for application. Failure to promptly consult your local
distributor, or Champion Customer Service, can be grounds to deny warranty.

LUBRICANT - ISO 100 MINERAL

CHAMPLUB ISO 100
DESCRIPTION PART NUMBER
1 – Quart Case (12/case) P09479A
1 – Gallon Case (4/case) P08909A
5 – Gallon Pail P08908A
55 – Gallon Drum P08907A

LUBRICANT - SYNTHETIC DIESTER

CHAMPLUB SYNTHETIC
DESCRIPTION PART NUMBER
1 – Quart Case (12/case) P13179A
1 – Gallon Case (4/case) P13180A
5 – Gallon Pail P11506A
55 – Gallon Drum P13181A

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Compressor Oil Specifications (continued)

LUBRICANT LEVEL:

Maintain lubricant level

at center of sight glass

BREAK-IN PERIOD: 100 hours of operation or 3 months, whichever comes first.

1. Compressor must run for the break-in period using CHAMPLUB ISO 100 lubricant.
2. During the break-in period, a careful and regular check of the oil level should be made. Maintain
oil level at the full line.
3. After the break-in period, thoroughly drain existing oil from crankcase.
4. Add a full charge of CHAMPLUB ISO 100 lubricant.

CHANGING TO SYNTHETIC DIESTER BASED LUBRICANT

If changing to synthetic lubricant, the following steps must be completed.

1. Compressor must run for the break-in period using CHAMPLUB ISO 100 lubricant.
2. During the break-in period, a careful and regular check of the oil level should be made. Maintain
oil level at the full line.
3. After the break-in period, thoroughly drain existing oil from crankcase.
4. Add a full charge of CHAMPLUB SYNTHETIC lubricant.
5. Run compressor for 200 hours.
6. Stop compressor and thoroughly drain the synthetic lubricant.
7. Add a full charge of CHAMPLUB SYNTHETIC lubricant.
8. Compressor is now ready to run for extended period before next lubricant change. Maintain oil
level at the full line.

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Guide to Maintenance
To obtain reliable and satisfactory service, this unit requires a consistent preventive maintenance
schedule. Maintenance schedule pages are included in the back of this manual to aid in keeping the
proper records.

Before performing any maintenance function, switch main disconnect switch to "off" position to
assure no power is entering unit. "Lock Out" or "Tag Out" all sources of power. Be sure all air
pressure in unit is relieved. Failure to do this may result in injury or equipment damage.

Do not exceed 15 PSIG nozzle pressure when cleaning element parts with compressed air. Do not
direct compressed air against human skin. Serious injury could result. Never wash elements in fuel
oil, gasoline or flammable solvent.

Never operate unit without belt guard in place. Removal will expose rotating parts which can cause
injury or equipment damage.

Valves must be reinstalled in original position. Valve gaskets should be replaced each time valves
are serviced.

PRESSURE RELIEF VALVE: The pressure relief valve is an automatic pop valve. Each valve is properly
adjusted for the maximum pressure permitted by tank specifications and working pressure of the
unit on which it is installed. If it should pop, it will be necessary to drain all the air out of the tank in
order to reseat properly. Do not adjust.

TANK DRAIN VALVE: Drain valve is located at bottom of tank. Open drain valve daily to drain
condensation. Do not open drain valve if tank pressure exceeds 25 PSIG. The electric tank drain-
equipped compressor requires draining manually once a week.

PRESSURE SWITCH: The pressure switch is automatic and will start compressor at low pressure and
stop when the maximum pressure is reached. It is adjusted to start and stop compressor at the
proper pressure for the unit on which it is installed. Only a certified field service technician should
make adjustments to the pressure switch.

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Guide to Maintenance (continued)

PILOT VALVE: The pilot valve actuates the head unloader mechanism to provide a means of stopping or
starting the compression of air by the compressor without stopping or starting the engine.

The pilot valve is pre-set from the factory, according to the order specification. Only a certified field
service technician should make adjustments to the pilot valve.

PILOT VALVE PRESSURE ADJUSTMENT

Proceed with the following instructions while compressor is running:

1. Loosen locknut (4) and back off several turns. Do not turn differential pressure adjustment nut
(3).
2. Check reading on the tank pressure gauge. Set the compressor maximum pressure by turning
threaded cap (1) clockwise to increase pressure or counter clockwise to decrease pressure.
3. After pressure is set, tighten locknut (4). Be careful not to move threaded cap (1).

PILOT VALVE DIFFERENTIAL PRESSURE ADJUSTMENT

Proceed with the following instructions while compressor is running:

1. Loosen locknut (2) and back off several turns.
2. Check reading on the tank pressure gauge. Set the pressure to 30 psig differential (unload at
170 psig, reload at 140 psig). Turn nut (3) clockwise to increase differential pressure or
counterclockwise to decrease differential pressure.
3. After pressure is set, tighten locknut (2). Be careful not to move nut (3).

1
4

3
2

MOUNTING ACTUATING TUBE

THREAD TO HEAD UNLOADERS

SENSING TUBE
FROM AIR RECEIVER

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Guide to Maintenance (continued)

COMPRESSOR VALVES: If compressor fails to pump air or seems slow in filling up tank, disconnect unit
from power source and remove valves and clean thoroughly, using compressed air and a soft wire
brush. After cleaning, exceptional care must be taken that all parts are replaced in exactly the same
position. All joints must be tight or the compressor will not function properly. When all valves are
replaced and connections are tight, close ball valve at tank outlet for final test. Valve gaskets should
be replaced each time valves are removed from pump.

CENTRIFUGAL UNLOADER AND UNLOADER PRESSURE RELEASE VALVE: The centrifugal unloader is
operated by two governor weights. It is totally enclosed and lubricated from the crankcase of the
compressor. When compressor starts, the governor weights automatically open, compressing the
main spring, allowing the unloader pressure release valve to close. When the compressor stops, the
main spring returns the governor weights to normal position, opening the unloader pressure release
valve and unloading the compressor. This prevents overloading the motor when starting. If air
continues to escape through the governor or unloader pressure release valve while operating, this is
an indication that the unloader pressure release valve is not closing tightly and may be held open by
a foreign substance which has lodged against the seat. In order to correct this, remove the governor
release valve cap, allowing access to unloader pressure release valve spring and ball. Clean
thoroughly and return parts in the same order in which they were removed. See Centrifugal
Unloader section in parts list for diagram. Loose drive belts can also cause unloader to leak by
preventing the compressor from reaching proper speed. (See “BELTS” page 24).

CHECK VALVE: The check valve closes when the compressor stops operating, preventing air from
flowing out of the tank through the pressure release valve. After the compressor stops operating, if
air continues to escape through the release valve, it is an indication that the check valve is leaking.
This can be corrected by removing check valve and cleaning disc and seat. If check valve is worn
badly, replace it.

Before removing check valve, be sure all air is drained out of tank and power is disconnected.
Failure to do so may result in injury or equipment damage.

THE INTERSTAGE PRESSURE RELIEF VALVE is provided to protect against interstage over pressure and is
factory set for maximum pressure of 75 PSIG. DO NOT RESET. If the pressure relief valve pops, it
indicates trouble. Shut down the unit immediately and determine and correct the malfunction.
Inspect the head valves. Serious damage can result if not corrected and can lead to complete
destruction of the unit. Tampering with the interstage pressure relief valve or plugging the opening
destroys the protection provided and voids all warranty.

COMPRESSOR LUBRICATION: Fill crankcase to proper level as indicated by oil sight gauge. Keep
crankcase filled as required by usage. It is recommended that only Champlub recip lubricant be
used. This is an ISO 100, non-detergent industrial oil with rust and oxidation inhibitors specially
formulated for reciprocating compressors. Do not mix oil types, weights, or brands.

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Guide to Maintenance (continued)

MOTOR LUBRICATION: Long life satisfactory operation of an electric motor depends in large measure
on proper lubrication of the bearings. Bearing grease will lose its lubricating ability overtime, not
suddenly. Refer to the motor manufacturer’s instructions for the type of grease and lubrication
intervals.

TORQUE VALUES:
Component Fastener Size & Thread Model Torque
Governor Housing 3/8-16 R10, R15 400 Inch-lb.
Governor Housing 7/16-20 R30, R40, R70 550 Inch-lb.
Cylinder Flange 7/16-20 R10, R15, R30 400 Inch-lb.
Cylinder Flange 1/2-13 R40, R70 900 Inch-lb.
Governor Spindle Screw 7/16-20 R10, R15, R30, R40, R70 470 Inch-lb.
Rod Bolt 5/16-18 R10, R15, R30 230 Inch-lb.
Rod Bolt 7/16-20 R40, R70 400 Inch-lb.
Manifold Cap Screw 3/8-16 R10, R15, R30 200 Inch-lb.
Manifold Cap Screw 7/16-14 R40, R70 230 Inch-lb.
Flywheel Pinch Bolt 1/2-13 R10, R15, R30 600 Inch-lb.
Flywheel Cap Screw 7/16-20 R40, R70 600 Inch-lb.

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Guide to Maintenance (continued)

SETTING BELT TENSION

1. Proper setting of the belt tension requires a belt tension checker (part number
TEN011452).
2. Measure the belt span.
3. On the belt tension checker, position the o-ring on the span scale at the measured
belt span.
4. Position the o-ring on the deflection force scale to zero.
5. Place a straight edge across the outside diameters of the motor pulley and
compressor flywheel.
6. Place the tension checker squarely on one belt at the center of the belt span. Apply
a force on the plunger, perpendicular to the belt span until the bottom of the large
o-ring is even with the bottom of the straight edge.
7. Remove the tension checker and read the force applied from the bottom of the
small o-ring on the deflection force scale.
8. Compare the force you have applied with the values given in the table on page 25.
The force should be between the minimum (used belt) and maximum (new belt)
shown.
9. Make adjustments to the location of the motor to achieve proper tension.

TEN011448-00
(Ref. Drawing)

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Guide to Maintenance (continued)

BELT DEFLECTION FORCE

MODEL H.P. PSI RPM MOTOR BELT BELT QTY USED BELT NEW BELT
PULLEY SECTION NUMBER OF DEFLECTION DEFLECTION
O.D. BELTS FORCE FORCE
(lbs. min) (lbs. max)
R10 2 125 535 5.15 B 63 2 3.4 4.9
R10 2 175 446 4.35 B 63 2 2.3 3.2
R10 3 125 825 7.75 B 65 2 3.4 4.8
R10 3 175 754 7.35 B 65 2 3.6 5.1
R15 5 125 780 7.35 B 65 2 3.1 4.4
R15 5 175 736 6.95 B 65 2 3.2 4.6
R15 7.5 125/175 959 8.95 B 68 2 3.7 5.3
R30 7.5 125 646 7.00 B 80 2 4.3 6.2
R30 7.5 175 568 6.20 B 80 2 4.8 6.9
R30 10 125 777 8.35 B 81 2 4.8 6.9
R30 10 175 758 8.15 B 81 2 4.8 7.0
R30 15 125/175 1049 11.15 B 85 2 5.4 7.8
R40 15 125 919 11.40 B 103 3 5.3 7.7
R40 15 175 782 9.75 B 100 3 5.9 8.5
R70 20 125 715 8.95 B 100 3 5.7 8.2
R70 20 175 665 8.35 B 100 3 6.0 8.7
R70 25 125 919 11.40 B 103 3 5.7 8.3
R70 25 175 782 9.75 B 100 3 6.4 9.3
R70 30 125/175 919 11.40 B 103 3 6.6 9.6

1. The values given in the “BELT DEFLECTION FORCE” table are calculated for nominal
conditions and are provided for reference only. The required tension may vary due to
application, manufacturing variances, component wear, etc. Drive belts must be kept tight
enough to prevent slipping. If belts slip or squeak, they need to be tightened.
2. Belt cross-section can be found printed on the outside surface of the belt.

If belts are too tight, overload will be put on motor and motor bearings.

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Maintenance Checklist

DAILY MAINTENANCE
Check oil level of both compressor and engine if equipped. Add quality lubricating oil as
1
required. See Section on "Oil Specifications".
Drain moisture from tank by opening tank drain valve located in bottom of tank. Do not open
2
drain valve if tank pressure exceeds 25 PSIG.
3 Turn off compressor at the end of each day's operation. Turn off power supply at wall switch.

WEEKLY MAINTENANCE
Clean dust and foreign matter from cylinder head, motor, fan blades, air lines, intercooler, and
1
tank.
2 Remove and clean intake air filters.

3 Check V-belts for proper alignment and tightness:

a Remove bolts and guard to access compressor drive.

b See “Setting Belt Tension” Section for details on how to check and set proper tension.
If necessary, loosen mounting hardware which secures motor to base. Slide motor within slots
c
of baseplate to achieve proper tension.
Check the alignment of pulleys. The compressor flywheel and motor sheave should be aligned
d
within ±1/2° with notched belts and ±2° with wrapped belts. Adjust if necessary.
e Tighten mounting hardware to secure motor on base.

f Re-install guard and secure with bolts.

EVERY 90 DAYS OR 500 HOURS MAINTENANCE

Change crankcase oil. Use type and grade oil as specified in the section on "Compressor Oil
1
Specifications".
Check entire system for air leakage around fittings, connections, and gaskets, using soap
2
solution and brush.
3 Tighten nuts and capscrews as required. See “Torque Values” section.
Check and clean compressor valves. Replace valves when worn or damaged. Replace valve
4
gaskets after each inspection.
5 Pull ring on all pressure relief valves to assure free movement.

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Troubleshooting Chart

Always disconnect unit from power supply and relieve all pressure from air tank before performing any
maintenance. Failure to do so may result in personal injury or death. “Lock Out" or "Tag Out" all power
sources.

Never operate unit without belt guard in place.

Never use gasoline or flammable solvent on or around compressor unit. Explosion may result.

Symptom Possible Cause(s) Corrective Action

Motor will not start. 1. Main switch and fuses open. 1. Check all fuses and switches. Check for
loose or faulty wires.
2. Starter magnetic coils open. 2. Check overload relay in starter. Reset
starter.
3. Thermal overload tripped. 3. Reset starter. If starter trips
repeatedly, have electrical system
inspected by an electrician.
4. Defective pressure switch-contacts 4. Repair or replace pressure switch.
will not close Warning – Relieve tank pressure
before servicing.
5. Check with voltmeter. Be sure voltage
5. Low voltage. corresponds to unit specifications.
Starter trips repeatedly. 1. Improperly adjusted pressure switch. 1. Adjust or replace.
Warning – Relieve tank pressure
before servicing.
2. Faulty check valve. 2. Clean or replace
Warning – Relieve tank pressure
before servicing.
3. Incorrect fuse size or magnetic 3. Be sure that fuses and coils are
starter coil. properly rated.
4. Low voltage. 4. Check with voltmeter. Be sure voltage
corresponds to unit specifications.
5. Defective motor. 5. Replace motor.
Tank pressure builds up slowly. 1. Air leaks. 6. Tighten fittings.
2. Dirty air filter. 7. Clean or replace.
3. Defective compressor valves 8. Install new valves.
Tank pressure builds up quickly. 1. Excessive water in tank. 1. Drain tank.
Discharge pressure relief valve 1. Wrong pressure switch setting. 1. Adjust to correct setting.
pops off while compressor is 2. Defective ASME relief valve. 2. Replace valve.
running. Warning – Relieve tank pressure
before servicing.
Compressor will not unload 1. Wrong pilot valve setting. 1. Adjust to correct setting.
(Units with head unloaders) 2. Defective pilot valve. 2. Replace pilot valve.
3. Lack of air to pilot valve. 3. Open ball valve to pilot valve.
Excessive belt wear. 1. Pulley out of alignment. 1. Realign motor pulley.
2. Belts too tight or too loose. 2. Adjust belt tension.
Compressor runs hot. 1. Improper flywheel rotation 1. Check for correct rotation.
(Counter clockwise when viewed from
drive side.)
2. Defective compressor valves. 2. Install new valve plate assembly.
3. Dirty air filter. 3. Clean or replace.
4. Dirty cylinder and/or intercooler. 4. Clean cylinder fins and/or intercooler.

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Troubleshooting Chart (continued)

Symptom Possible Cause(s) Corrective Action
Interstage pressure relief valve 1. Defective compressor valves. 1. Install new valves.
pops off. 2. Improper valve installation. 2. Verify proper valve placement.
Excessive oil consumption. 1. Dirty air filter. 1. Clean or replace.
2. Wrong oil viscosity. 2. Refill with proper viscosity oil.
3. Oil leaks. 3. Tighten bolts. Replace gaskets.
4. Worn piston rings. 4. Replace rings.
5. Scored cylinder 5. Replace cylinder.
Air escapes from centrifugal 1. Centrifugal unloader release valve 1. Clean or replace valve
unloader when unit is running dirty or detective.
Air escapes from centrifugal 1. Check valve stuck in open position. 1. Replace check valve.
unloader when unit is stopped. Warning – Relieve tank pressure
before servicing.
System does not alternate 1. Starter tripped. 1. Reset starter. If starter trips repeatedly,
(Duplex units only) have electrical system inspected by an
electrician.
2. Loose wiring in alternator. 2. Check and tighten all wiring
connections.
3. Defective alternator. 3. Replace alternator.
4. Defective motor. 4. Replace motor.

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Maintenance Log

DAILY
● CHECK OIL LEVEL
● DRAIN MOISTURE FROM TANK
WEEKLY MONTHLY EVERY 3 MONTHS
● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL
● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES
● TIGHTEN ALL FASTENERS
● TEST PRESSURE RELIEF VALVE

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Maintenance Log

DAILY
● CHECK OIL LEVEL
● DRAIN MOISTURE FROM TANK
WEEKLY MONTHLY EVERY 3 MONTHS
● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL
● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES
● TIGHTEN ALL FASTENERS
● TEST PRESSURE RELIEF VALVE

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Maintenance Log

DAILY
● CHECK OIL LEVEL
● DRAIN MOISTURE FROM TANK
WEEKLY MONTHLY EVERY 3 MONTHS
● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL
● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES
● TIGHTEN ALL FASTENERS
● TEST PRESSURE RELIEF VALVE

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

For additional information, contact your local representative or visit:

www.championpneumatic.com/contactus.aspx

©2019 Gardner Denver, Inc. Printed in U.S.A.

MCGUIRE AIR COMPRESSORS INC 1-888-229-9999