OIL-LESS SCROLL AIREND – 3.7/5.

5kW & 7kW

OPERATION/MAINTENANCE MANUAL & PARTS LIST

3.7kW (5 HP) / 5.5kW (7.5HP) 7.5kW (10 HP)

CC1213688 CC1213690

Form No. CC1220019 Ver: 00 12/01/2021

 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. 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: https://www.championairtech.com/

Or

Call: +39 0331 349411

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.
TABLE OF CONTENTS

Safety And Operation Precautions ........................................................................................................................... 4

Explanation Of Safety Instructions Symbols And Decals............................................................................................ 5
Warranty................................................................................................................................................................. 6
Theory Of Operation................................................................................................................................................ 8
Specifications .......................................................................................................................................................... 9
Installation .............................................................................................................................................................10
Maintenance ............................................................................................................................................. 12 thru 25

3
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.
Before you install the air compressor you should take the time to carefully read all the instructions contained in this
manual. Electricity and compressed air have the potential to cause severe personal injury or property damage. Before
installing, wiring, starting, operating or making any adjustments, identify the components of the air compressor using
this manual as a guide.
The operator should use common sense and good working practices while operating and maintaining this unit.
Maintenance should be done by qualified personnel, accurately and with proper tools. Follow the maintenance
schedule as outlined in the manual to ensure problem free operation after start up.
In addition to the many obvious safety rules that should be followed with this type of machinery, the safety precautions
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 Occupational Safety and Health Act
OSHA) and EN Standards EN 1012-1-2010 and EN60204-1 and the requirements of the Machinery Directive.
2A) An electrical disconnect is not supplied with this unit. It is the customer’s responsibility to provide an electrical
disconnect in accordance with 5.3 of EN 60204-1:2006. See nameplate for applicable electrical information.
2B) Over-current protections of the unit shall be supplied by customer in accordance with 7.2 of EN60204-1:2006.
See nameplate for applicable electrical information.
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 into 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. "Tag Out" or "Lock 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 the 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. 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.
14. 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.
15. Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic fumes.
16. 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 as modern motors are built to operate at
higher temperatures.
17. Inspect unit daily to observe and correct any unsafe operating condition.
18. Do not "play around" with compressed air, nor direct air stream at body, because this can cause injuries.
19. Personal injury could result if there is direct contact of compressed air.
20. Never direct compressed air onto your own skin or at other people. Never use compressed air to clean loose dirt
from clothing.
21. Compressed air from this machine must not, under any circumstances, 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 a compressed air tool.

The user of any air compressor package manufactured by Champion is hereby warned that failure to follow the
preceding Safety and Operation Precautions can result in injuries or equipment damage. However, Champion 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

4
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 PARTS LIST SECTION.

This Oil-Less 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.

5
WARRANTY
STANDARD WARRANTY
Champion (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the
Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, free of defects in
material and workmanship.
STANDARD WARRANTY PERIOD
The Company’s obligation under this warranty is limited to repairing or, at its option, replacing, during normal business
hours at an authorized service facility of the Company, any part which in its judgment proved not to be as warranted
within the applicable warranty period as follows. Regular maintenance in accordance with the service manual is
required. Use of genuine Champion OEM parts and lubricants are highly recommended. If a component
failure is deemed a result of using non-genuine Champion parts and lubricants, warranty will not be allowed.

COMPONENT STANDARD WARRANTY COVERAGE DETAILS

12 months from startup or 15 months from date of All components within the package, excluding normal
Package
shipment to first purchaser, whichever occurs first. wear items.
Normal wearing items, along with the service of these
items is not covered under the warranty unless
12 months from startup or 15 months from date of deemed as material or workmanship defects. Any
Airend
shipment to first purchaser, whichever occurs first. disassembly or partial disassembly of the airend, or
failure to return the “unopened: airend per Company
instructions, will cause for denial or warranty.
Includes both drive motor and cooling fan motor. For
Electric 12 months from startup or 15 months from date of
nonstandard motors, the original manufacturer’s
Motor shipment to first purchaser, whichever occurs first. warranty will take precedence.
Major Package 12 months from startup or 15 months from date of Includes package controller, variable frequency drive
Components shipment to first purchaser, whichever occurs first. if applicable, and air cooler.
Service will be provided by Company representative
or authorized service personnel, for repair or
replacement of any product or part which in the
Company’s sole judgement is proved not to be as
Package / Electric Motors 12 months from startup warranted. Labor shall be limited to the amount
or 15 months from date of shipment to first specified in the Company’s labor rate schedule. All
purchaser, whichever occurs first. costs of transportation of product parts and repaired
Labor or replacement parts claimed not to be as warranted
Airend/Major Package Components: 12 months to and from such service facilities shall be borne by
from startup or 15 months from date of shipment Purchaser. The Company may require the return of
to first purchaser, whichever occurs first. any part claimed to be as warranted to one of its
facilities as designated by Company, transportation
prepaid by Purchaser, to establish a claim under this
warranty are warranted for the remainder of the
Warranty Period.

NO WARRANTY IS MADE WITH RESPECT TO:

1. ANY PRODUCT WHICH HAS BEEN REPAIRED OR ALTERED IN SUCH A WAY, IN THE COMPANY’S JUDGMENT, AS TO
AFFECT THE PRODUCT ADVERSELY
2. ANY PRODUCT WHICH HAS, IN THE COMPANY’S JUDGMENT BEEN SUBJECT TO NEGLIGENCE, ACCIDENT,
IMPROPER STORAGE, OR IMPROPER INSTALLATION OR APPLICATION
3. ANY PRODUCT WHICH HAS NOT BEEN OPERATED OR MAINTAINED IN ACCORDANCE WITH THE
RECOMMENDATIONS OF THE COMPANY
4. ANY RECONDITIONED OR PRIOR OWNED PRODUCT

6
STANDARD WARRANTY DISCLAIMER

THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE,
THE COMPANY MAKES NO OTHER WARRANTIES AND HEREBY EXPRESSLY DISCLAIMS ALL OTHER
WARRANTIES, INCLUDING WITHOUT LIMITATION, EXPRESSED, IMPLIED OR STATUTORY WARRANTIES,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE. 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 CONSEQUENTIAL DAMAGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER
CAUSED. NO STATEMENT, REPRESENTATION, AGREEMENT, OR UNDERSTANDING, ORAL OR WRITTEN,
MADE BY ANY AGENT, DISTRIBUTOR, REPRESENTATIVE, OR EMPLOYEE OF THE COMPANY WHICH IS NOT
CONTAINED IN THIS WARRANTY WILL BE BINDING UPON THE COMPANY UNLESS MADE IN WRITING AND
EXECUTED BY AN OFFICER OF THE COMPANY. THIS WARRANTY SHALL NOT BE EFFECTIVE AS TO ANY
CLAIM WHICH IS NOT PRESENTED 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 WITHIN ONE YEAR AFTER THE DATE UPON WHICH THE CAUSE OF ACTION OCCURRED. ANY
ADJUSTMENT MADE PURSUANT TO THIS WARRANTY SHALL NOT BE CONSTRUED AS AN ADMISSION BY
THE COMPANY THAT ANY PRODUCT WAS NOT AS WARRANTED. WARRANTY IS NOT TRANSFERRABLE

7
THEORY OF OPERATION

A scroll compressor uses two interwoven scrolls. One of the scrolls is fixed, while the other orbits
eccentrically without rotating, thereby compressing pockets of air between the scrolls. The diagram
below illustrates the normal operation of the scroll compressor.

As the orbiting scroll moves, several gas pockets are formed simultaneously between the two scrolls.
Pockets at the outer part of the scrolls (inlet 1 & 2) intake gas and move it towards the center of the
scroll. As the gas moves through continuously smaller internal pockets, both its temperature and
pressure are increased until a desirable discharge pressure is achieved and the compressed gas is
discharged thought the exhaust port located in the center.

8
SPECIFICATION

MODEL p/n: CC1213688 p/n: CC1213690

Maximum Pressure 8.3 bar 10 bar 8 bar 10 bar 8 bar 10 bar
(120psi) (145psi) (116psi) (140psi) (116psi) (140psi)
14.1 CFM 13.4 CFM 21.48 CFM 15.7 CFM 31 CFM 25 CFM
ACFM
(24m3/h) (22.78 m3/h) (36.5 m3/h) (26.8 m3/h) (52.7 m3/h) (43 m3/h)
Maximum Discharge
414 °F (230 °C)
Temp
Shaft Power 3.7kW (5.5 HP) 5.6kW (7.5HP) 7.5kW (10HP)
Shaft Rotational Speed 2430 rpm 2046 rpm 3325 rpm 2686 rpm 3773 rpm 3234 rpm
Belt Section 3VX
Number of Belts 2
Air Intake Port Size 3/4” GAS F
Air Discharge Port Size 3/8” GAS M 1/2” GAS M
Max. ambient
40°C (104°F)
temperature
Min. ambient
0°C (32°F)
temperature
Heat Rejection 11950 BTU/h (3.5 kW) 17100 BTU/h (5 kW) 23000 BTU/h (6.74 kW)
Ambient Humidity 30 – 80% (Relative humidity)
Weight 61lb (27.7kg) 62lb (28kg)

NOTE:
1. Performance given is applicable up to 1,640ft (500m). Above 1,640ft (500m), specification will be
different.

9
INSTALLATION

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

 Do not install in an area where ambient temperature is below 0°C (32°F) or above 40°C
(104°F).
 Do not install unit in an area where air is dirty and/or chemical laden.
 Unit is not to be installed outdoors.
 Do not install the system in an area subject to foreign matter, such as: iron powder, sand
dust, powdered dust, wood chips, textile waste, stone powder, and fine iron powder
fumes.
 Do not install the system in an area of close proximity to explosives and/or flammable
gases, such as acetylene, propane gas, organic solvents, explosive powdered dust
and/or fire.
 Do not install the system in an area where corrosive gases are present, such as; organic
solvents (benzene, toluene, etc.), acid, chloride gas, ozone gas, ammonia, significant oil
mists and/or bromine.

NOTICE
The discharge nipple is hand tightened only. Make sure to tighten the discharge nipple when
installing the airend.

1. Install a properly sized inlet filter to prevent debris entering the scroll compressor. A 5 micron
filter is recommended.

2. Install a check valve directly after the outlet side of the compressor to prevent air flowing back
into the compressor.

3. Install a pressure relief valve in the discharge air piping to protect the system from abnormal
pressure rise.

4. Make sure that the airend is securely bolted down and all piping and fittings are securely
fastened before starting the scroll compressor.

5. Compressors should never be located so close to a wall or other obstruction that flow of air
through the cooling fan, which cools the compressor, is impeded. Permanently mounted
units should have cooling fan at least 24” from wall for proper air circulation and ease of
maintenance.

6. Before placing airend in service, check rotation.

10
Correct rotation is counter-clockwise, when viewed from the compressor pulley on the airend (A), and
clockwise rotation when viewed from the discharge outlet (B).

A B

Running the unit in wrong direction longer than two (2) seconds will result in damage to the
Scroll compressor, and void the warranty.

11
MAINTENANCE

COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS. BEFORE DOING ANY WORK ON
THE UNIT, BE SURE THE ELECTRICAL SUPPLY HAS BEEN SHUT OFF (LOCKED AND TAGGED)
AND THE ENTIRE COMPRESSOR SYSTEM HAS BEEN VENTED OF ALL PRESSURE. FAILURE
TO DO THIS MAY RESULT IN INJURY AND DAMAGE TO THE SYSTEM.

12
AIREND MAINTENANCE TABLE – 8 bar (116 PSI)
Maintenance and Inspection Time Interval
Inspection Every Every
Component Every 500 Every 2,000 Remarks
Instructions 10,000 20,000
Daily Hours or 2 Hours or 1
Hours or 4 Hours or 8
Months Year
Years Years
Inspect for
Complete
Scroll Airend
excessive noise □
and vibration.
Clean, inspect &
Replace every
Intake Air Filter replace as □ ○ 2,000 hours
needed
Cooling Fan &
Scroll Fin
Clean & Inspect □
Replace the airend
Re-grease the
Scroll Bearings
bearing. ■ if bearings are
damaged
Tip Seals &
Face Seals
Replace the
seals. ○
Brushes Replace
(7kW ONLY) the Drum ○
Replace the
Scroll Airend
scroll airend. ◎
1. □ Clean and inspect the item according to the procedure outlined in the cleaning section.
2. ■ Re-grease the bearings according to the procedure outlined in the regressing sections.
3. ○ Replace the item.
4. ◎ Replace the scroll airend.
5. Maintenance and inspections should be performed when the operating hours and/or calendar date
is reached, whichever occurs first.
6. If the compressor is operating at full pressure and is constantly running, reduce the service
intervals by 25%.
7. Maintenance time intervals shown are for normal operating conditions. For operating conditions
where ambient temperature is higher than 77 °F (25 °C), the maintenance intervals are reduced as
shown in Figure 1 below. (6kW ONLY).

FIGURE 1

13
 AIREND MAINTENANCE TABLE – 10 bar (140 PSI)
Maintenance and Inspection Time Interval
Inspection Every 500 Every 2,000 Every 5,000 Every 10,000 Every 15,000
Component Remarks
Instructions Daily Hours or Hours or Hours or Hours or Hours or
2 Months 1 Year 2 Years 4 Years 6 Years
Inspect for
Complete Scroll
excessive noise □
Airend
and vibration.

Clean, inspect & Replace every

Intake Air Filter □ ○
replace as needed 2,000 hours

Cooling Fan &

Clean & Inspect □ □
Scroll Fin
Replace the
Re-grease the airend if
Scroll Bearings ■ ■
bearings. bearings
are damaged.
Tip Seals &
Replace the seals. ○ ○
Face Seals
Brushes Replace
○ ○
(7kW ONLY) the Drum
Replace the scroll
Scroll Airend ◎
airend.
1. □ Clean and inspect the item according to the procedure outlined in the cleaning section.
2. ■ Re-grease the bearings according to the procedure outlined in the regressing sections.
3. ○ Replace the item.
4. ◎ Replace the scroll airend.
5. Maintenance and inspections should be performed when the operating hours and/or calendar
date is reached, whichever occurs first.
6. If the compressor is operating at full pressure and is constantly running, reduce the service
intervals by 25%.
7. Maintenance time intervals shown are for normal operating conditions. For operating conditions
where ambient temperature is higher than 77 °F (25 ℃), the maintenance intervals are reduced as
shown in Figure 2 below. (6kW ONLY).

FIGURE 2

14
MAINTENANCE TOOLS

Tools for service:

1. Phillips screw driver (＋ cross-tip)

2. Metric socket set, extension, ratchet handle
3. Plastic hammer
4. Seal pick
5. Feeler gauge 0.02 in (0.5 mm)
6. Low pressure clean dry air 90psi (6.2 bar) MAX
7. Torque wrench (in-lbs) 100 to 260 in-lbs (11.3 to 29.4 Nm)
8. Spring Scale McMaster-Carr p/n: 1757T38 or similar
9. Kit, 10HP Brushes & Springs p/n: 302SIA6003
10. Kit, Service 5.5 - 7.5 HP Scroll p/n: 300SIA6003
(Includes Tip Seal, Face Seal, & Grease)

11. Kit, Service 10HP Scroll p/n: 301SIA6003

(Includes Tip Seal, Face Seal, Grease, Brushes & Springs)

12. Grease gun ** p/n: 300SMB6031

*Grease is supplied with the seal kit. Refer to the grease delivery chart on page (20) to
calculate the amount of grease required to perform the maintenance service. Use only factory
approved grease. Failure to do this may result in damage to the compressor and will void the
warranty.
** Use only the factory approved grease gun to perform the maintenance service. Failure to do
this may result in damage to the compressor and will void the warranty.

15
DISASSEMBLY
1. Remove the side duct.

2. Remove the fan duct cover by removing nine 9 (6mm) screws

3. Clean the cooling fan. Blow dust off the cooling fan using low pressure, clean dry air.

Blow dust off the fixed and orbiting scroll fin using low pressure, clean dry air.

Clean the cooling fan before disassembling the fixed scroll to prevent dust entering into
compression area.

Do not use excessive force or strike the pulley when trying to remove it.

16
 4. Disassembly the fixed scroll

Allow airend to cool before disassembly to eliminate tightness of knock-pin due to thermal
expansion.

Note: Apply lubricant to knock-pin to facilitate disassembly.

Knock-pin

5. Loosen the four (4) (M10) nuts 1 turn. Nuts are marked to identify number of turns.

1 revolution

Turn Mark

Nut (M10)

6. Using a plastic hammer, gently tap the fixed scroll, keeping it parallel with the casing.

7. Repeat 5 through 6 (7 times) until the fixed scroll can be removed from the casing.

Do not damage scroll wrap during and after removing the fixed scroll.

17
8. Remove tip seals from fixed and orbiting scrolls.

Do not damage scroll wrap when disassembling the tip seals, face seal, and back-up tube.

9. Remove the face seal and back-up tube from the fixed scroll.

REGREASING THE BEARINGS

NOTICE
Use only factory approved grease. Failure to do so may result in damage to the compressor
and will void the warranty.

1. Regrease the main shaft bearing and three (3) support bearings.

Support bearings (3 places) Main shaft bearing

2. Remove the rubber plug.

Rubber plug

18
3. Clean grease nipples before injecting grease.
4. Inject grease into the main shaft bearing using the grease gun specified on page 15.

Refer to page 20 for the correct amount of grease.

5. Inject grease into the support bearings using the grease gun specified on page 15.

Refer to page 20 for the correct amount of grease.

19
 Table 1. Amount of supplying grease 8 bar [116 PSI]
Amount of supplying grease
Item 0h～ 2,501h～ 5,001h～ 7,501h～
2,500h 5,000h 7,500h 10,000h
Main shaft 5 strokes 9 strokes 13 strokes 15 strokes
bearing (2.8±0.3 g) (5.0±0.5 g) (7.3±0.6 g) (8.4±0.6 g)
3.7kW (5.5
HP) Support bearings 1 stroke 2 strokes 3 strokes 4 strokes
(3 places) (0.6±0.1 g) (1.1±0.1 g) (1.7±0.2 g) (2.2±0.2 g)
Main shaft 5 strokes 9 strokes 13 strokes 15 strokes
bearing (2.8±0.3 g) (5.0±0.5 g) (7.3±0.6 g) (8.4±0.6 g)
6 kW
(7.5 HP) Support bearings 1 stroke 2 strokes 3 strokes 4 strokes
(3 places) (0.6±0.1 g) (1.1±0.1 g) (1.7±0.2 g) (2.2±0.2 g)

Main shaft 5 strokes 11 strokes 16 strokes 22 strokes

bearing (2.8±0.3 g) (6.2±0.4 g) (9.0±0.5 g) (12.3±0.6 g)
7 kW
(10 HP) Support bearings 1 stroke 2 strokes 3 strokes 5 strokes
(3 places) (0.6±0.1 g) (1.1±0.1 g) (1.7±0.2 g) (2.8±0.2 g)

Table 2. Amount of supplying grease 10 bar [140 PSI]

Amount of supplying grease
Item 0h～ 1,251h～ 2,501h～ 3,751h～
1,250h 2,500h 3,750h 5,000h
Main shaft 5 strokes 9 strokes 13 strokes 15 strokes
bearing (2.8±0.3 g) (5.0±0.5 g) (7.3±0.6 g) (8.4±0.6 g)
3.7kW (5.5
HP) Support bearings 1 stroke 2 strokes 3 strokes 4 strokes
(3 places) (0.6±0.1 g) (1.1±0.1 g) (1.7±0.2 g) (2.2±0.2 g)
Main shaft 5 strokes 9 strokes 13 strokes 15 strokes
bearing (2.8±0.3 g) (5.0±0.5 g) (7.3±0.6 g) (8.4±0.6 g)
6 kW
(7.5 HP) Support bearings 1 stroke 2 strokes 3 strokes 4 strokes
(3 places) (0.6±0.1 g) (1.1±0.1 g) (1.7±0.2 g) (2.2±0.2 g)
Main shaft 5 strokes 11 strokes 16 strokes 22 strokes
bearing (2.8±0.3 g) (6.2±0.4 g) (9.0±0.5 g) (12.3±0.6 g)
7 kW
(10 HP)
Support bearings 1 stroke 2 strokes 3 strokes 5 strokes
(3 places) (0.6±0.1 g) (1.1±0.1 g) (1.7±0.2 g) (2.8±0.2 g)

Note:
1) Do not inject grease into each bearing beyond specified amount shown in above
table, otherwise the bearings are damaged.
2) The amount of grease should be determined based on operating time
mentioned below.

1st Time: Operating time from start operation.

2nd Time: Operating time from the last time maintenance.

20
6. Install the rubber plug using pliers.

Pull out the plier while pressing the rubber plug with
finger

REPLACING THE BRUSH [10 HP Only]

1. Remove brushes from orbiting scroll side and shaft side.
Replace brushes and re-assemble.
Do not lose the washer.
Torque Bolts: 11Ft-lbs (15 N-m)

Orbiting scroll side Shaft side

21
REASSEMBLY
1. Install the tip seals and face seal

Make sure to install tip seals in the right direction, because the orbiting scroll tip seals and
the fixed scroll tip seals are different.

Direction of Rip

Center of wrap

Scroll wrap
A. Install outside tip seal.
 Push the inner end of the outside tip seal to the outer end of the inside tip seal and then install
the tip seal into the groove.
 Make sure the end of the outside tip seal fits in a projection of the groove.

Projection

B. Install inside tip seal filling the gap between the outside and inside tip seals.

Outside Inside

Fill the gap

Do not push the tip seals to bottom of groove.

Install tip seal in the groove with 1mm protruding from edge of groove.

22
C. Install back-up tube and face seal. Install so the seams of the face seal and back-up tube are 180
degrees from each other.

2. Assemble the fixed scroll on the two (2) knock-pins.

Note the direction of the fixed scroll. The gap between the fixed Scroll and the casing surface
should be 2mm or less.

If the gap between the fixed scroll and the casing is more than 2 mm or is not parallel,
there is a possibility that the tip seals or face seal are not installed in the groove properly.
Disassemble the fixed scroll and repeat the process to install the tip seals or face seal properly.

3. Tighten the four (4) M10 nuts: 22ft-lbs (30N-m).

4. After assembling the fixed scroll to the casing, turn the shaft by hand to confirm the smooth
rotation of the shaft.

23
5. After installing the fixed scroll, measure the torque of the shaft Coil a piece of string around the
pulley and then connect a spring scale to the other end of the string. Turn the pulley more than
one complete turn by pulling the scale. Take measurements of the scale, and calculate the
average.

Measure only the rolling force. Do not count the starting force. If the torque of the shaft
exceeds 4.85lb (2.2 kg) replace the airend.

6. Assemble the side duct

7. Assemble the fan duct cover

24
Re-tightening discharge piping

Refer to the following procedure to re-tighten discharge piping after maintenance of air-end if
discharge pipe was removed.

1. Hand-tighten the discharge pipe.

2. Put a reference line on the discharge pipe to count turns.

3. Using a wrench, tighten the discharge pipe the number of turns shown in the table below.

Over tightening of discharge pipe will cause damage to pipe thread and airend.

Air-end
Nominal pipe
Model Additional turns
diameter
6kW (7.5HP) 3/8 4 to 4.5
7kW (10HP) 1/2 3 to 3.5

Discharge pipe
Reference line
Other
 Inspection of the air-end

1. Rotation of bearings
If the main shaft does not rotate smoothly, replace the air-and.

2. Condition of scroll wrap

If the scroll wraps have contacted each other or been scratched, replace the scroll air-end.

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NOTES:
NOTES:
For additional information, contact your local representative or visit:
https://www.championairtech.com

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