Champion D5 Manual

D5-MANS
Mar ’19
- 1 -
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.
D5
Rotary Screw
Air Compressor
Units
- - -
Installation
And
Service Data
Contents Page
Quick Start ……………............................................. 2
Safety Precautions …………………………………… 4
Unpacking and Inspection …………………………... 5
Installation – Mechanical ……………………………. 6
Lubrication ……………………………………………. 8
Installation – Electrical ………………………………. 9
Motor maintenance instructions ……………………. 11
Start-up Procedures …………………………………. 12
Preventative Maintenance Schedule ………………. 13
Maintenance procedures ……………………………. 15
‘CSC15’ Controller……………………………………. 22
Common Compressor Faults …………….…………. 26
Separator Filter and Refrigerated Air Dryer………… 27
Troubleshooting Guide ………………………………. 30
Warranty ………………………………………………. 33
Please read this manual before
installing or using your Air
Compressor Unit. It contains
valuable information that will
help in the receiving,
installation, use, and
maintenance of the Unit.
Please keep this manual in a
safe place for future reference.
All of the information, policies, and
procedures in this reference manual apply
exclusively to Champion.

D5-MANS
Mar ’19
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Quick Start
Mechanical Installation
(Refer to Page 6)
Lubrication Rotation
(Refer to Page 8) (Refer to Page 10)
18”
[458mm]
18”
[458mm]
The Unit must be located indoors, in a dry, clean, cool,
dust free, and well ventilated area.
Allow a minimum 18” (458mm) around and 36” (915mm)
above Unit.
The ambient temperature should be between 10°C and
40°C (50°F and 104°F).
Ensure that the floor under the Unit is smooth, level and
capable of bearing the weight of the Compressor.
If installed in a compressor room, ensure that the room is
adequately ventilated.
The unit must be anchored to the floor using isolator pads.
Ensure the oil level in the Air End is between the
top (maximum) or bottom (minimum) thread as
shown.
The correct rotation is as shown.
The Unit is equipped with an Anti-Rotation
Switch. Check that the rotation is correct.
Drain condensate (water) from oil tank.
If compressor work-cycle experiences long
pauses, condensate will gather in oil tank.
Drain condensate EVERY 50HRS OR WEEKLY.
(Refer to Page 8 for details)
36”
[915mm]
Installation Kit
IK515
Flex-Hose &
Vibration Isolators
(sold separately)
18”
[458mm]
Unit
Nameplate
Model No.
Serial No.
Unit voltage

D5-MANS
Mar ’19
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Quick Start (cont’d)
Unit Operation
Shown below is the ‘CSC15’ Controller which regulates the operation of the Unit. Unit Status LEDs, Hour Meter,
and ON/OFF switch are located on the control panel cover.
Starting the Unit: Turn the Selector Switch to ‘ON’ position.
Stopping the Unit: Turn the Switch to ‘OFF’ position, unit will unload for 10 seconds prior to stopping.
Note:
1. Do not stop the Unit by use of a disconnect or breaker.
Power Light
Turns on when power
has been applied to the
unit.
Hour Meter
Displays the number of
running hours.
Using the disconnect, or breaker to stop the Unit will not allow the Unit to go
through an unloading sequence, and could result in damage to the Motor, Starter,
or other electrical components. Damage caused in this manner is not covered by
the manufacturers Warranty.
Start / Stop Switch
ON position:
Starts compressor
OFF position:
Compressor unloads for 10
seconds and then stops
Fault Light
Compressor fault indicator:
ON Solid = Anti-Rotation
Fast Flash = Power Interruption
Slow Flash = Service Due*
Two Flashes = High Temp Fault
Three Flashes = Overload Fault
*Depress ‘Reset’ button within
cabinet to clear fault.

D5-MANS
Mar ’19
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Safety Precautions
In order to operate the Compressor Unit safely and correctly, we have opted to use the following symbols to make
you aware of important points. These points relate to user safety and preventing equipment problems. Please pay
close attention to these sections.
The following hazards may occur during the normal use
of the equipment. Please read the following chart.
Area: Hazard: Safeguards:
What may occur if precautions are not
observed.
Tampering with the Unit while under Relieve all pressure from the Unit
full or partial pressure may cause an before attempting any repair or
explosion. maintenance work.
As the Unit starts and stops Shut off all power to the Unit before
automatically, serious injury may attempting to repair or maintain
result from working on the Compressor the Compressor.
with the power still in the 'on' position.
As the Unit starts and stops Shut off all power to the Unit before
automatically, do not come into attempting to repair or maintain
contact with moving parts. the Compressor.
Air compressed by the Unit is not Never breath untreated compressed
suitable for inhaling. It may contain air produced by the Compressor.
vapours harmful to your health. Do not direct air stream at body.
Compressor capable of pressures >50psi
Compressor Air End, Motor, and Never touch the Air End, Motor, or
Tubing become hot when running. Tubing during or immediately after
Touching these areas may cause operation.
serious burns.
As the electrical components on the Do not install in hazardous locations.
Compressor are General Purpose, The Compressor must be a minimum
there is a potential for explosion, should of 20 feet (6.1 meters) from any source
vapours be present in the area. of potentially explosive vapours.
What to look for. How to avoid the hazard.
2 0 F T
6 . 1 m
Important safety Information.
A hazard that may cause
serious injury or loss of life.
Important information that
indicates how to prevent
damage to equipment, or how
to avoid a situation that may
cause minor injury.
Information that you should
pay special attention to.

D5-MANS
Mar ’19
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Unpacking and Inspection
It is the responsibility of the receiver of the goods, either the Distributor or Customer, to ensure that the product
has been shipped in full, and has arrived in suitable condition. Damage to the product may not be visible at time
of off-loading, but may only become apparent upon unpacking or start-up.
Some areas to initially check are as follows:
a) Check for damage to the crating and/or packaging.
b) Check the exterior of the Cabinet for damage, either cosmetic or mechanical.
c) If there is mechanical damage, open the Cabinet to determine whether there is any internal
damage to the Unit.
Should there be damage to the product or shortages in shipment:
1) Stop any further unpacking or operation of the product.
2) Make note of the problem on the Freight Bill, should it concern a shortage or visible
damage to the product.
3) Should the damage be noticed only after the product has been received, contact the
transport company immediately to file a claim.
Depending on the problem, it may be wise to photograph the damage. Also, it may
be wise to discuss with the carrier representative the time allotted to give notice of loss
or damage to the product; there may be guidelines which limit timeframes of same.
4) Do not attempt further unpacking or operation of the product. Also, do not discard
any packing material used.
5) A Loss or Damage Claim must be submitted to the carrier and supported by the
following documents:
- Copy of Freight Bill of Lading
- Copy of the Invoice and Estimate to repair, in case of damage
- Damage Report
- Copy of photos, if applicable
Each Champion Air Compressor is carefully tested and inspected
before shipment. Though every attempt is made to ensure the safe
and complete shipment of our product, freight damage or
misplacement of goods may occur.
Shipments of Champion products are the property of the
Consignee when the products leave our facility. Champion is not
responsible for any damages or shortages caused to the product
after it has left our shipping dock.

D5-MANS
Mar ’19
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The Compressor must not be operated in
a confined area where the heat from the
Unit cannot readily escape.
Installation – Mechanical
Moving of the Unit
When moving the Air Compressor, the
forklift or hand lift forks go under the Unit
from the directions as indicated.
Please be advised that care must be taken
when moving and positioning the Units as
they are top heavy.
Location of the Unit
Items to consider when installing the Unit are as
follows:
The Unit must be located indoors, in a dry, clean,
cool, dust free, and well ventilated area. If
possible, the Compressor should be located in
a separate room or area, away from the
general operations of the shop.
Allow approximately a minimum of 18” (458mm)
around and 3 feet (915mm) above the Unit for
easy access to the various sides, this being for
both the proper ventilation of the Unit and ease
of servicing.
Ensure that the floor under the Unit is smooth,
level and capable of bearing the weight of the
Compressor. The Compressor must sit
squarely on the floor.
Ensure that the Unit is anchored to the floor using
isolator pads.
If installed in a compressor room, ensure that the
room is adequately ventilated. (One
Horsepower produces approximately 2500
BTU/HR.)

The ambient temperature should be between
10°C and 40°C (50°F to 104°F).
If installing the Unit on a mezzanine, ensure that
the structure can safely support the weight of
the Unit. As well, the sound level of the Unit
may increase due to the harmonics created by
the structure; use Vibration Pads to lessen this.
When anchoring the Unit, ensure that there is
approx.. ¼” (0.75cm) between the Nut and the
Compressor Foot (as shown below). Do not
bolt down tightly.
Many common Compressor problems can be
attributed to the location or installation of the Unit.
Make sure the Unit is in a suitable location, and
installed correctly.
Compressor
Foot
¼” (0.75 cm)
Gap
Floor
Isolator
Pad

D5-MANS
Mar ’19
- 7 -
Installation – Mechanical (cont’d)
Shown below are items which assist in making a good installation. These are both intake and exhaust ductwork,
helping the Unit to a) draw in clean outside air and b) exhaust the warmer air away from the Unit. The warmer air
may be used, with the inclusion of a damper in the exhaust ducting, to warm the interior of the building during the
colder months of the year.
TYPICAL DUCTING INSTALLATION LAYOUT

D5-MANS
Mar ’19
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Lubrication
Air End
Initial Start-up
Each Compressor Unit built is extensively tested at
the factory before shipment. The Unit is shipped with
the original oil in it as used for testing purposes.
Check the Oil level and for any Oil leaks on a daily
basis. This must be done when the Unit is off. Top up
the Oil level on a monthly basis.
Use only Champion lubricant. Also, do not mix the
Champion lubricant with any other lubricant.
Subsequent Oil Changes
Drain the existing oil from the Unit. (Please be
advised that the Unit cannot be drained fully of oil, as
some oil may remain in various components ie
Cooler, Tubing, etc.)
Fill the Oil Reservoir to the top of the Oil Fill Port as
shown below. Do not under or overfill. See drawing
below.
Use only Champion lubricant, available in both 1 US
gallon (3.8 litre) jugs or 5 US gallon (18.9 litre) pails.
Any remaining oil may be used for ‘top-ups’.‘
The ‘MK-D5-CH’ Maintenance Kit includes:
(2) Oil Filter (’DSC-603-CH’)
(1) Air/Oil Separator Filter (’DSC-002832-CH’)
(2) Air Filters (’DSC-001569’)
(1) Oil Sample Kit (‘308KBA6003’)
This Kit should be used in the regular servicing of
your Unit.
Do not attempt to operate the Unit without
first checking whether there is oil in the Air
End Reservoir. Add oil as required. Serious
damage may result from use, however
limited, without oil.
Use of improper oil may negatively affect
Compressor performance or shorten Unit life.
Resulting problems are not covered by the
Champion Air Compressor Warranty.
Condensation (water) may form in the Air End
if the compressor work cycle experiences
long pauses. If this occurs, the condensate
MUST be drained EVERY 50HRS OR
WEEKLY:
- Wait for compressor to cool for approx.
2HRS.
- Remove service panel
- Slowly open the oil drain valve on the air
end & drain condensate
- When the first traces of oil appear, close
the cap/valve
- Top up the Air End with new oil using only
Champion lubricant.
Oil Drain

D5-MANS
Mar ’19
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Installation - Electrical
When making power and control wiring connections, please observe the following precautions:
Ensure that all wiring, fusing, etc is done in a manner that meets with the appropriate codes and
regulations.
See the sales drawing and electrical schematic contained in this booklet for Unit amp draw, as well as
Unit fuse sizes and overload settings.
A licensed Electrician is to determine the appropriate Disconnect/Breaker and wiring sizes based on the
Unit amp draw and the appropriate Electrical Code.
General Information
It is your responsibility to ensure that the Compressor
Unit is electrically connected in a safe and correct
manner. Any electrical work should be carried out
by a competent Electrician, and be done in such
a way that it meets all applicable Codes and
Regulations.
Ensure that a suitable Fused Disconnect or Breaker
is installed in the electrical supply before the
Compressor Unit.
Ensure that a suitable Fused Disconnect or Breaker
is sized and installed according to the appropriate
local electrical codes.
Electrical wiring and conduit from the building supply,
through the Compressor Cabinet, and to the Switch
in the Compressor Control Panel, must be rated for
90°C (194°F) or higher.
Failure to observe any of the above precautions could result in severe personal injury or death,
and/or damage to the Unit.
Failure to correctly connect the
Compressor to your building's electrical
services may result in serious personal
injury or damage to the equipment.
Install all covers and panels before
applying power to the Unit.
Failure to install proper fuse protection
may void the unit warranty
Before servicing the Unit, ensure the
power source has been shut down and
locked off.
Read and understand the information
contained in this manual before installing
or operating the Unit.
This product must be connected to a
grounded, metallic, permanent wiring
system, or an equipment-grounding
terminal or lead on the product.
Wiring Practices
Fixed Speed Units:
Use TIME-DELAY type fuse.
Max. Allowable Fuse = 1.75 x Motor Full Load Amp

D5-MANS
Mar ’19
- 10
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Installation – Electrical (cont’d)
Wiring must be done in a manner that 230 volts +/- 5% is available at the Motor terminals during start-up. Contact
your local Distributor or Service Centre if additional information is needed.
The Warranty that exists on the Electric Motor is that of the original manufacturer. In the event of a Motor failure,
locate a certified EISA motor service centre.
Electrical Connection
The Electrician is to bring
power to the Unit through
the ¾” conduit hole
located on the top of the
unit. The Electrical Panel
is accessible by means of
opening the Front Control
Panel Cover.
Connect ground wire to
Protective Earth terminal.
Bring power to L1 and L2.
See page 12 for start-up
procedures
Motors. Motors
Do not attempt to operate the Unit without first checking whether there
is oil in the Air End Reservoir. Add oil as required. Serious damage may
result from use, however limited, without oil.
It is critical that the Motor and Air End in the
Rotary Screw Unit be turning in the correct
manner. Irreparable damage will be done if the
Unit rotates in the opposite direction. The correct
rotation is shown at right.
The Unit is equipped with an Anti-Rotation
Switch. If the Unit will not start and an ‘Anti
Rotation’ error is noted on the Controller, change
the connections at the motor connection box to
the following:
Motor L#1 & Motor L#5 with Harness Black
Motor L#4 & Motor L#8 with Harness White
Motor/Air End Rotation
Bring power to
Terminal Blocks
L1, L2
Starter
Overload Relay
PLC
Protective
Earth

D5-MANS
Mar ’19
- 11
-
Motor Maintenance Instructions
Cleaning
To ensure that the Motor operates at optimum temperatures and provides years of trouble-free service,
periodically clean the outside of the Motor Housing of any build-up of dust, etc. Though it is not anticipated that, if
installed correctly and in a suitable environment, there should not be much build-up on the Motor, keeping the
Housing clean will allow the Motor to operate more efficiently.
Lubrication
This is a ball bearing motor. The bearings have been lubricated at the factory. Motors that do not have regrease
capability are factory lubricated for the normal life of the bearings.
Noted below is a chart outlining the interval at which the Motor should be lubricated, this is based on the Motor
horsepower. This must be part of a regular maintenance schedule.
Motor HP Interval Weight of Grease Volume of Grease
in Hours Ounces Grams Cubic Inch Teaspoon
5 12,000 0.3 8.4 0.6 2.0
The above chart is based on a standard environment in which the Motor is operating of 40°C. For other
conditions, please multiply the Hour Interval from the chart above by the factor as indicated below.
Severity of Duty Factor Environmental Conditions
Standard 1.0 40°C (104°F), clean, little corrosion
Severe 0.5 50°C(122°F), moderate dirt, corrosion
Extreme 0.1 > 50°C (122°F), severe dirt, abrasive dust
Low Temperature 1.0 < 30°C (86°F)
Lubricant
Motors are pre-greased, normally with Exxon Mobil Polyrex EM. Equivalent and compatible grease is Chevron
SRI #2.

D5-MANS
Mar ’19
- 12
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Start-up Procedures
Unit Controls
Initial Start-up
1) Remove the RH Side Access Panel, and
ensure that there is sufficient Oil in the Air
End. Refer to the ‘Lubrication’ section (page
8) in this manual for proper type and level of
Oil.
2) Do a visual inspection of the Unit, and ensure
that no internal damage was caused during
transit.
3) Place the Fused Disconnect or Breaker in the
‘On’ Position. Check that there is power to
the Controller, the green Power light will be
on.
4) During normal operation of the Unit, keep the
Access Panels closed at all times. As well,
do not place any obstructions against or on
top of the Unit, thereby limiting the flow of
cooling air.
5) Ensure the Ball Valve on the Unit is closed,
turn the Selector Switch to the ‘On’ position,
and run the Unit up to maximum pressure.
The Unit will run up to 145 psi (10bar), at
which point the Motor will continue to run but
not compress air.
6) Once the Unit reaches 145 psi (10bar), it will idle for 1
minute and shut off.
Default Offload Time of this unit is 1 minute. It would
switch from 1 minute to 3 minutes if rate of pressure
decay is high.
7) Open the Ball Valve slightly and allow the air to bleed
from the Tank. Once the pressure reaches approx.
110 psi (7.6bar), the Unit will start and begin to
compress air after a short delay.
8) Measure the amp draw when the Unit reaches the
maximum pressure of 145 psi (10bar).
9) Close the Ball Valve, allow the Unit to reach
maximum pressure, idle, and shut off.
10) The Unit is ready for normal use.
11) To validate Warranty, complete the warranty
registration and attach to the on-line startup claim
within Thirty (30) days of initial operation, or
email to:
‘[email protected]’
Shut off all power to the Air
Compressor Unit before attempting any
repair or maintenance.
Adjusting the settings of the Controller
could adversely affect the performance
of the Unit. Only those individuals with
knowledge of the Unit should make any
adjustments.
Start/Stop Switch
Start position:
allows the Unit to
start.
Stop position:
unit will shutdown
after 10 secs.
Do not place any materials in close
proximity to the Compressor. Placing
materials against or close to the Unit
will limit the cooling required, and
could lead to premature failure.

D5-MANS
Mar ’19
- 13
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Preventative Maintenance Schedule
Noted on the following pages are general Maintenance guidelines based on average working conditions. Should
the Unit be worked under extreme conditions, please contact your Champion Distributor for further input. As well,
all maintenance/service work must be carried out by a qualified Technician.
The typical operating temperature of the Unit, this dependant on ambient temperatures, is between 70ºC and
85ºC (158ºF and 185ºF).
If the operating temperature of the Unit is too low (less than 70°C (158°F)):
condensation will build up in the system and mix with the oil, causing internal component problems in the
Unit
Change the ambient conditions to increase the operating temperature.
If the operating temperature of the Unit is too high (above 85°C (185°F)):
the oil will oxidize and lose it’s properties, this causing internal damage to components as well
to combat this, the oil must be changed more often than noted below.
When servicing the Air Compressor, shut off all
power to the Unit, and drain it of air pressure.
It is the responsibility of the compressor owner
to ensure that a regular Maintenance Schedule
is followed.
Note: Participation in Champion’s oil analysis sampling program is required to receive the
extended warranty. Any recommendations detailed in the oil analysis report must be
followed as outlined in the report.
Regular Maintenance Items
‘MK-D5-CH’ 4000 Hour Maintenance Kit
(2) DSC-603-CH Oil filter
(1) DSC-002832-CH Air/Oil Separator Filter
(2) DSC-001569 Air Filter
(1) 308KBA6003 Oil Sample Kit
Lubricant Options
Champion offers various lubricants for your unit,
available in quantities of 5 US Gal. (18.9 litre) pails:
RotorLub 8000
RotorLub 8000TH
RotorLub 4000
RotorLub 4000FG
RotorLub 4000FG-68
Internal Access for Maintenance
The internal components of the Unit are accessible for
servicing by way of removing the RH Side Panel.
The Back Panel is also removable to access the Belts.
Remove the plastic cap to change air/oil separator filter.

D5-MANS
Mar ’19
- 14
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Preventative Maintenance Schedule (cont’d)
Maintenance Item: Daily Maintenance Interval (in 000’s of Hours)
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Compressor Room
Temperature Inspect Ambient Temperature should be between 10°C and 40°C (50°F and 104°F)
Cleanliness Inspect
Air Compressor Unit
Check Oil Level Inspect
Take Oil Sample (See Note a) X X X X X X X X X X X X X X X X X X X X
Replace Oil (See Note b) (1) X X X X X X X X X X
Replace Oil Filter (2) X X X X X X X X X X X X X X X X X X X X
Replace Air / Oil Separator (3) X X X X X X X X X X
Replace Air Intake Filter (4) X X X X X X X X X X X X X X X X X X X X
Replace Belt (5) X X X X X
Replace Tank Relief Valve X X X
Replace Solenoid (6) X X X X X
Rebuild Intake Valve (7) X X X X X
Rebuild Thermo Valve (8) X X X X X X
Rebuild Minimum Pressure Valve (9) X X X X X
Motor Bearing Lubrication Refer to Motor Manufacturer’s Recommendations
Notes: a) Participation in Champion’s oil analysis sampling program is required to receive the extended
warranty. An oil sample must be sent to our lubricant analysis laboratory every 2000 hours or every
6 months, whichever occurs first. Any recommendations detailed in the oil analysis report must be
followed as outlined in the report. Oil sample bottles are to be obtained from your local authorized
Champion distributor.
b) The Champion oil used in the maintenance schedule is rated as a 4000 hour oil. A complete Oil
change must be done every 4000 hours of Unit operation, or every 12 months, whichever occurs first.
If other champion lubricant is used, please refer to the Warranty on Page 33 for further information.
c) If a component, during a regular inspection, has proven to be defective or unfit for regular operation, it
must be repaired or replaced.
Parts and Repair Kits based on the above chart are as follows:
(1) RotorLub 4000 oil: 28H116
(2) Oil Filter: DSC-603-CH
(3) Air / Oil Separator: DSC-002832-CH
(4) Air Intake Filter: DSC-001569
(5) Belt (1): DSC-002820
(6) Solenoid with Cable: DSC-002885 (up to AE S/N SC272839)
DSC-002957 (above AE S/N SC272839)
(7) Intake Valve Repair Kit DSC-001712
(8) Thermo Valve Repair Kit: DSC-002057
(9) Minimum Pressure Valve Kit: DSC-001713
Shaft Seal Kit DSC-002835
As noted previously, the ‘MK-D5-CH’ Maintenance Kit includes the following items:
(2) DSC-603-CH Oil Filter
(1) DSC-002832-CH Air/Oil Separator Filter
(2) DSC-001569 Air Filter
(1) 308KBA6003 Oil Sample Kit

D5-MANS
Mar ’19
- 15
-
Maintenance Procedures
Changing the Air / Oil Separator
1) If necessary, use a strap wrench to turn the
original Separator counter-clockwise.
2) On the new ‘DSC-002832-CH’ Air / Oil
Separator, lubricate the Separator Gasket with
Compressor Oil.
3) Hand tighten the new Air / Oil Separator snug
Note:
Do not over-tighten the Separator Filter on the
Unit, as it may become very difficult to remove at a
later date.
Changing the Oil Filter
The Oil Filter should be changed only after all of the oil
has been drained from the Unit.
1. Ensure that you have a bucket and strap wrench
available.
2. Holding the bucket under the original Oil Filter to
capture any spillage, use the strap wrench to turn
the Oil Filter counter-clockwise. The Oil may still
contain oil, so care must be taken.
3. On the replacement ‘DSC-603-CH’ Oil Filter,
lubricate the Filter Gasket with Compressor Oil.
4. Hand tighten the Oil Filter snug.
Changing the Air Intake Filter
1) Remove the Nut holding the Top half of the
Housing and then remove the Top.
2) Remove the Air Filter Element from the Unit.
3) Clean the Intake Valve area of any dust or
build-up.
4) Install a new Air Filter (Champion Part Number
‘DSC-001569’), place the Element Top on the
Filter, and fasten down with the Wing Nuts.
Note:
Depending on the quality of the air in the
compressor room, it may be necessary to check
and/or change the Air Filter more often than
indicated on the 'Maintenance Schedule'.

D5-MANS
Mar ’19
- 16
-
Maintenance Procedures (cont’d)
Air End
Oil Drain
Cleaning the Heat Exchanger
The circulation of air through the Heat Exchanger is
critical to the correct operation of the Unit. Clean the
Heat Exchanger on a regular basis.
1. Remove the Back Panel.
2. Vacuum the Heat Exchanger as necessary.
Note:
When cleaning the Heat Exchanger, do not use sharp
objects or a wire brush. These items could damage the
cooling coils.
Heat
Exchanger
Oil Changes
Drain the existing oil by turning the Oil Drain Tube down and opening the
Valve. (Please be advised that the Unit cannot be drained fully of oil, as
some oil may remain in various components ie Cooler, Tubing, etc.)
Close the Drain Valve.
Fill the Oil Reservoir to the top of the Oil Fill Port as shown below. Do not
under or overfill. See drawing below.
Use only Champion lubricant.

D5-MANS
Mar ’19
- 17
-
Maintenance Procedures (cont’d)
Adjusting the Drive Belts
This unit is equipped with a Belt Tensioning Device that constantly maintains the proper drive tension for the Belt.
The loosening and tightening of the Drive Belt is done by way of moving the Belt Tensioning Roller up or down on
the belt, respectively.
To loosen the belt tension, simply turn the Hand Wheel
counter-clockwise. This will allow the Belt Tensioning
Roller to lift off of the Belt.
To tighten the belt tension, simply turn the Hand Wheel
clockwise. This will compress the Tension Spring and
push the Belt Tensioning Roller down further onto the
Belt.
Note: The Belts (new) should be tensioned as
follows:
HP Deflection Frequency
New After Run
5
10mm
deflection
with 40N at
centre span
(.39” with
9 Lb Force)
96 Hz 93 Hz
Spring
Belt
Hand
Wheel
Roller
Using a Frequency Analyzer
After the belts have been installed it is recommended that
the belt tension be set to a frequency listed in the above
table. To obtain the correct frequency the use of a
Frequency Analyzer ‘FA-9000’ is recommended.
1. Place the belts over the air end and motor pulleys.
2. Place the Roller onto the belt as shown above.
3. Turn the Hand Wheel clock-wise to tighten the spring
and push the Roller onto the Belt.
4. Check the frequency of the Belt with the Frequency
Analyzer:
a. Place the microphone of the Frequency
Analyzer close to the Belt
b. Push the ‘On’ button
c. Pluck the belt
d. The Frequency Analyzer will make a tone
and the frequency will displayed on the
screen
5. Adjust the Spring as required repeating steps 3 & 4.

D5-MANS
Mar ’19
- 18
-
Maintenance Procedures (cont’d)
Intake Valve Repair Kit
The Intake Valve Assembly is located directly below the Intake Filter, and should be rebuilt after a maximum of
10,000 hours of Unit operation. Please order (1) ‘DSC-001712 Intake Valve Repair Kit. Shown below are the
various components associated with the Intake Valve Repair Kit.
A
Intake Valve Open Intake Valve Closed
A
A: Air Inlet
B: Air Outlet
C: Control Line of Intake Valve
C

D5-MANS
Mar ’19
- 19
-
Maintenance Procedures (cont’d)
Thermo Valve Repair Kit
The Thermostatic Valve Assembly is located at the back of the Air End and to the bottom
left of the pulley, and should be rebuilt after a maximum of 6,000 hours of Unit operation.
Please order (1) ‘DSC-002057’ Thermo Valve Repair Kit
Thermo Valve Operation
The Thermostatic Valve Assembly helps to maintain an optimum oil
temperature in the Unit, allowing the hotter oil (once the Unit reaches
operating temperature) to flow through the Heat Exchanger.
This is as indicated below.
When Oil is Cool at
Start-up.
As Unit Reaches
Operating
Temperature.
Hot Oil to Heat Exchanger
Cool Oil
from Heat Exchanger

D5-MANS
Mar ’19
- 20
-
Maintenance Procedures (cont’d)
Minimum Pressure Valve Repair Kit
The Minimum Pressure Valve is located beside the Air Oil
Separator, and a) acts to ensure there is a back-pressure of
approx. 80 psi (5.5bar) to provide sufficient lubrication in the Air
End and b) acts to stop compressed air from flowing backwards ie.
as a one-way Valve. Please order (1) ‘DSC-001713’ Minimum
Pressure Valve Repair Kit.
Shown at right are the various components included in the Kit.
Shaft Seal Kit
Please order (1) ‘DSC-002835’ Shaft Seal Kit. Shown below are the
various components included in the Kit.
‘DSC-002835’ Shaft Seal Kit