Gardner Denver CHAMPION ROTORCHAMP EFB99B Service manual

CHAMPION®13-8-620
V
ersion: 10
May 2, 2006
ROTORCHAMP
BASE-MOUNTED
COMPRESSORS
MODELS – EFB99B, EFB99G
7.5, 10 & 15 HP
OPERATING AND
SERVICE MANUAL

13-8-620 Page i
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 local authorized distributor maintains a large inventory of
genuine parts and he is backed up for emergency parts by direct access to the Master Distribution Center (MDC) in Memphis,
Tennessee.
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. Factory warranted new and remanufactured rotary screw airends. Most popular model remanufactured airends are maintained
in stock at Champion for purchase on an exchange basis with liberal core credit available for the replacement unit.
3. A full line of factory tested RotorLub™ compressor lubricants specifically formulated for use in Champion compressors.
4. 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.
For the location of your local authorized Champion Air Compressor distributor, refer to the yellow pages of your phone
directory or contact:
Factory:
Champion
1301 N. Euclid Ave.
Princeton, Il 61356
Phone: [phone]
Fax: [phone]
REMANUFACTURED AIRENDS
Whenever an airend requires replacement or repair, Champion offers an industry unique, factory remanufactured airend exchange
program. From its modern Remanufacturing Center in Indianapolis, IN., Champion is committed to supplying you with the highest
quality, factory remanufactured airends that are guaranteed to save you time, aggravation and money.
Immediately Available
Repair downtime costs you money, which is why there are over 200 remanufactured units in inventory at all times, ready for
immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, inspected and analyzed. Only those parts that can be brought back to original
factory specifications are remanufactured. Every remanufactured airend receives a new overhaul kit: bearings, gears, seals,
sleeves and gaskets.
Extensive Testing
Champion performs testing that repair houses just don’t do. Magnaflux and ultrasonic inspection spot cracked or stressed castings,
monochromatic light analysis exposes oil leaks, and coordinate measurement machine inspects to +/- .0001”, insuring that all
remanufactured airends meet factory performance specifications.
Warranty
Champion backs up every remanufactured airend with a new warranty…27 months from purchase, 24 months from service.
Champion remanufactured airends deliver quality without question…year in and year out.
Call Champion for information on the airend exchange program and the name of your authorized distributor.
Phone Number: [phone]
Fax: [phone]

13-8-620 Page ii
FOREWORD
Champion Rotary Screw compressors are the result of advanced engineering and skilled manufacturing.
To be assured of receiving maximum service from this machine the owner must exercise care in its
operation and maintenance. This book is written to give the operator and maintenance department
essential information for day-to-day operation, maintenance and adjustment. Careful adherence to these
instructions will result in economical operation and minimum downtime.
DANGER
Danger is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored.
WARNING
Warning is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard which will or can cause
minor personal injury or property damage if the warning is ignored.
NOTICE
Notice is used to notify people of installation, operation or maintenance
information which is important but not hazard-related.
This book covers the following models:
HP PSI Air Cooled Parts List
7.5, 10 & 15 100, 125, 150, 175 EFB99B 13-8-514
7.5, 10 & 15 100, 125, 150, 175 EFB99G 13-8-535

13-8-620 Page iii
TABLE OF CONTENTS
Maintain Compressor Reliability And Performance With
Genuine Gardner Denver Compressor Parts And Support Services .......................................................i
Remanufactured Airends ...............................................................................................................................i
Foreword....................................................................................................................................................... ii
Index............................................................................................................................................................. iv
List Of Illustrations........................................................................................................................................ vi
Section 1, General Information .....................................................................................................................1
Section 2, Installation....................................................................................................................................7
Section 3, Starting & Operating Procedures...............................................................................................14
Section 4, Controls & Instrumentation ........................................................................................................17
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator............................................................................24
Section 6, Air Filter......................................................................................................................................34
Section 7, Belt Drive....................................................................................................................................35
Section 8, Maintenance Schedule ..............................................................................................................38
Section 9, Troubleshooting .........................................................................................................................40

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INDEX
Air Control Components...................................18
Changing Minimum Pressure/Check Valve
Seals.........................................................19
Inlet Valve.....................................................18
Minimum Pressure/Check Valve..................18
Solenoid Valve..............................................18
Air Cooled Unit...................................................7
Air Filter
Element.........................................................34
Element Life..................................................34
Section 6.......................................................34
Standard Duty...............................................34
Air Flow In Compressor System ........................1
Air Receiver
Auxiliary........................................................10
Belt Drive
Replacing Belts.............................................35
Section 7.......................................................35
Belt Tension
Checking.......................................................37
Cold Weather Operation ..................................10
Cold Weather Operation, Installation For.........10
Compression Principle.......................................1
Compressor........................................................1
Connection To External Controls.....................22
Control Box And Controller ..............................19
Controls & Instrumentation
General.........................................................17
Operation......................................................17
Section 4.......................................................17
Cooling, Sealing And Lubrication.......................1
Daily Check......................................................16
Decals ............................................................5, 6
Discharge Service Line....................................11
Electrical Wiring ...............................................11
Enclosure ...........................................................9
Foundation .........................................................8
General Information
Section 1.........................................................1
Grounding.........................................................12
Hourmeter ........................................................19
Inlet Line...........................................................10
Inlet Valve.........................................................18
Installation
General...........................................................7
Section 2.........................................................7
Lifting Unit ..........................................................7
Location .............................................................7
Lubricant Upgrade Procedure..........................27
Lubrication
Motor............................................................12
Lubrication Oil Cooler, Oil Filter & Separator ..24
Section 5 ......................................................24
Lubrication, Cooling And Sealing.......................1
Maintenance Schedule
Section 8 ......................................................38
Minimum Pressure/Check Valve......................18
Changing Seals............................................19
Moisture Separator/Trap
Optional........................................................10
Motor Lubrication.............................................12
Oil Change Interval..........................................25
Oil Cooler
Compressor..................................................30
Oil Filter
Compressor..................................................29
Oil Level
Procedure For Checking..............................24
Oil Level Gauge...............................................29
Oil Reservoir....................................................31
Drain...............................................................8
Filling............................................................26
Oil Separator
Compressor..................................................31
Inspection.....................................................32
Pressure Differential Gauging......................31
Removal For Inspection Or Replacement....32
Oil System
Addition Of Oil Between Changes................24
Cold Ambient Operation...............................24
Compressor..................................................24
Draining And Cleaning.................................26
High Temperature Operation .......................24
Moisture In System ......................................29
Procedure For Checking Oil Level...............24
Recommended Lubricant.............................24
Specifications...............................................24
Oil System Check ............................................33
Air And Oil Discharge Temperature.............33
Compressor Oil Inlet Temperature...............33
Oil Cooler Oil Pressure Differential..............33
Oil Cooler Temperature Differential.............33
Oil Inlet Pressure..........................................33
Piping
Control..........................................................10
Prestart-Up Instructions...................................14
Air Filter........................................................14
Compressor Oil ............................................14
Electrical.......................................................14
Enclosure .....................................................15

13-8-620 Page v
Grounding.....................................................14
Operating Mode............................................15
Piping............................................................14
Rotation ........................................................14
System Pressure..........................................15
Relief Valve......................................................17
Sealing, Lubrication And Cleaning.....................1
Separator
Compressor Oil.............................................31
Separator/Trap
Moisture
Optional.....................................................10
Service Check List ...........................................38
Air Filter ........................................................38
Every 1000 Hours Operation........................38
Every 125 Hours Operation..........................38
Every 150 Hours Operation..........................38
Every 4000 Hours Operation........................38
Every 8 Hours Operation..............................38
Every Year....................................................38
Motor Lubrication..........................................38
Setting The Load/Unload Pressure Setpoints..20
Auto Time .....................................................21
Automatic Restart.........................................21
Temperature Shutdown................................22
Sheave Alignment............................................36
Sheave And Shaft Seal
Replacing......................................................36
Solenoid Valve.................................................18
Starter/Control Box...........................................19
Hourmeter ....................................................19
Starting & Operating Procedures
Section 3 ......................................................14
Starting The Unit..............................................15
Unit Cold.......................................................15
Unit Hot ........................................................15
Stopping The Unit............................................16
Thermal Control (Thermostatic Mixing) Valve.31
Troubleshooting
Section 9 ......................................................40
Troubleshooting Auto Sentry T Electronic
Controller......................................................42
Green Automatic Mode Indicator.................42
Green Power-On Indicator...........................42
High Voltage Indication................................43
Other Controls Troubleshooting...................44
Red Compressor Temperature Fault Indicator
..................................................................43
Troubleshooting Voltage Problems..............43
Yellow High/Low Temperature Warning ......42
Valve
Inlet...............................................................18
Minimum Pressure/Check............................18
Relief............................................................17
Solenoid .......................................................18
Thermal Control (Thermostatic Mixing)........31
Wiring
Electrical.......................................................11

13-8-620 Page vi
LIST OF ILLUSTRATIONS
Figure 1-1 – Compressor Cycle....................................................................................................................1
Figure 1-2 – Compressor Illustration.............................................................................................................2
Figure 2-1 – Typical Compressor Room.......................................................................................................8
Figure 2-2 – Air Flow Chart...........................................................................................................................8
Figure 2-3 – Cold Weather Installation .........................................................................................................9
Figure 4-1 – Control Schematic ..................................................................................................................18
Figure 4-2 – Maximum Setpoint For Nema 4 Pressure Switch...................................................................21
Figure 4-3 – Wiring Diagram.......................................................................................................................23
Figure 5-1 – Approximate Oil System Capacities.......................................................................................25
Figure 5-2 – Oil Change Interval.................................................................................................................26
Figure 5-3 – Oil Level Gauge......................................................................................................................29
Figure 5-4 – Air Flow Through The Reservoir, Air/Oil Separator & Minimum Pressure Check Valve........30
Figure 6-1 – Standard Duty Air Filter..........................................................................................................34
Figure 7-1 – Drive Sheave..........................................................................................................................35
Figure 7-2 – Belt Tension – J Section Micro-V Belts ..................................................................................37

13-8-620 Page 1
SECTION 1
GENERAL INFORMATION
Figure 1-1 – COMPRESSOR CYCLE
COMPRESSOR - The rotary screw compressor is a single stage, positive displacement rotary machine
using meshing helical rotors to effect compression. Both rotors are supported between high capacity
roller bearings located outside the compression chamber. Single width cylindrical roller bearings are
used at the inlet end of the rotors to carry part of the radial loads. Ball and roller bearings at the
discharge end locate each rotor axially and carry all thrust loads and the remainder of the radial loads.
COMPRESSION PRINCIPLE (Figure 1-1) - Compression is accomplished by the main and secondary
rotors synchronously meshing in a one-piece cylinder. The main rotor has five (5) helical lobes 72°apart.
The secondary rotor has six (6) matching helical grooves 60°apart to allow meshing with main rotor
lobes.
The air inlet port is located on top of the compressor cylinder near the drive shaft end. The discharge port
is near the bottom at the opposite end of the compressor cylinder. Figure 1-1 is an inverted view to show
inlet and discharge ports. The compression cycle begins as the rotors unmesh at the inlet port and air is
drawn into the cavity between the main rotor lobes and the secondary rotor grooves (A). When the rotors
pass the inlet port cutoff, air is trapped in the interlobe cavity and flows axially with the meshing rotors (B).
As meshing continues, more of the main rotor lobe enters the secondary rotor grove, normal volume is
reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of compression and seal internal clearances. Volume
reduction and pressure increase continues until the air/oil mixture trapped in the interlobe cavity by the
rotors passes the discharge port and is released to the oil reservoir (C). Each rotor cavity follows the
same “fill-compress-discharge” cycle in rapid succession to produce a discharge air flow that is
continuous, smooth and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 5-4, page 30) - Air enters the air filter and passes
through the inlet unloader valve and on into the compression chamber where oil is injected into the air.
After compression, the air/oil mixture passes into the oil reservoir where most of the entrained oil is
removed by velocity change and impingement and drops back into the reservoir. The air and remaining
oil then passes through the air/oil separator. The air then passes through the minimum pressure/check
valve, the aftercooler and the moisture separator and into the plant air lines.
LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through
the oil cooler, thermostatic mixing valve, and oil filter and discharge into the compressor main oil gallery.
A portion of the oil is directed through internal passages to the bearings and shaft oil seal. The balance
of the oil is injected directly into the compression chamber to remove heat of compression, seal internal
clearances and lubricate the rotors.

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13-8-620 Page 2
300EFB797-A
(Ref. Drawing)
Figure 1-2 – COMPRESSOR ILLUSTRATION

13-8-620 Page 3
SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or
circumstances cannot always be predicted and covered by established rules. Therefore, use your past
experience, watch out for safety hazards and be cautious. Some general safety precautions are given
below:
DANGER
Failure to observe these notices could result in injury to or death of personnel.
• Keep fingers and clothing away from revolving fan, drive coupling, etc.
• Do not use the air discharge from this unit for breathing – not suitable for
human consumption.
• Do not loosen or remove the oil filler plug, drain plugs, covers, the
thermostatic mixing valve or break any connections, etc., in the compressor
air or oil system until the unit is shut down and the air pressure has been
relieved.
• Electric shock can and may be fatal.
• Perform all wiring in accordance with the National Electrical Code (NFPA-70)
and any applicable local electrical codes. Wiring and electrical service must
be performed only by qualified electricians.
• Open the main disconnect switch, lockout and tagout before working on the
control.
• Disconnect the compressor unit from its power source, lockout and tagout
before working on the unit – this machine is automatically controlled and
may start at any time.

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WARNING
Failure to observe these notices could result in damage to equipment.
• Stop the unit if any repairs or adjustments on or around the compressor are
required
• Disconnect the compressor unit from its power source, lockout and tagout
before working on the unit – this machine is automatically controlled and
may start at any time.
• An Excess Flow Valve should be on all compressed air supply hoses
exceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302, or
local regulations)
• Do not exceed the rated maximum pressure values shown on the nameplate.
• Do not operate unit if safety devices are not operating properly. Check
periodically. Never bypass safety devices.

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DECALS
206EAQ077
212EAQ077
218EAQ077
211EAQ077
207EAQ077

13-8-620 Page 6
DECALS
216EAQ077
217EAQ077
222EAQ077
221EAQ077 208EAQ077

13-8-620 Page 7
SECTION 2
INSTALLATION
GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit.
Report any damage or missing parts as soon as possible.
CAUTION
Do not electric weld on the compressor or base; bearings can be damaged by
passing of current.
LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Unit may
be moved into location by lift truck.
CAUTION
Lift compressor unit under base only. Do not use other places such as motor,
compressor or discharge manifold piping as lifting points.
DANGER
The eyebolts or lugs provided on the motor are for lifting the motor only and
should not be used to lift any additional weight. All eyebolts must be securely
tightened. When lifting the motor the lifting angle must not exceed 15 degrees.
Failure to observe this warning may result in damage to equipment or personal
injury.
LOCATION (Figure 2-1, page 8) - The compressor should be installed where it is protected from rain,
snow and freezing temperatures, in a clean, well-lighted, well-ventilated area with ample space all around
for maintenance. Select a location that provides a cool, clean, dry source of air. In some cases it may be
necessary to install the air filter at some distance from the compressor to obtain proper air supply.
AIR-COOLED UNIT - A combination oil/aftercooler is supplied as standard equipment on all air-cooled
units. The air-cooled unit with the standard enclosure requires sufficient flow for the compressor
oil/aftercooling system and electric motor cooling (Figure 2-2, page 8). Air is drawn into the unit above
the motor and discharged through the cooler. Do not block the air flow to and from the unit. Allow three
and one half (3-1/2) feet to the nearest obstruction on the control box end of the unit. Allow two (2) feet to
the nearest obstruction above and on other sides of unit.
For continuous efficiency, oil cooler cores must be periodically cleaned with either vacuum or compressed
air. If wet cleaning is required, shield motor and spray on a mild soap solution and flush with clean water.

13-8-620 Page 8
WARNING
For aluminum oil coolers, do not use any cleaning solution that is not
compatible with aluminum. Use of improper solution may result in damage to
the cooler.
Figure 2-1 – TYPICAL COMPRESSOR ROOM
Minimum Air Flow* For Compressor
And Cooling (cubic Feet/Minute)
Air Cooled
All Models 3000 cfm
*80°F Inlet Air
Figure 2-2 – AIR FLOW CHART
FOUNDATION - The rotary screw compressor requires no special foundation, but should be mounted on
a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be
made at a maximum 5°angle lengthwise or 5°sidewise. Mounting bolts are not normally required.
However, installation conditions such as piping rigidity, angle of tilt, or danger of shifting from outside
vibration or moving vehicles may require the use of mounting bolts and shims to provide uniform support
for the base. Belt alignment and tension should be checked after installation. (For information on belt
alignment and tension, see SECTION 7, page 35.
OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir to the side of the frame.
This drain is approximately 20 inches above the floor level.

13-8-620 Page 9
CAUTION
If the compressor unit base is raised above floor level, the space between the
floor and the base bottom must be closed with solid material all around to
prevent recirculation of hot air from the oil cooler end and over temperature
operation.
ENCLOSURE - The compressor, electric motor, oil cooler and aftercooler are mounted inside the
enclosure.
Service panels are provided for maintenance access. Be sure to allow enough space around the unit for
the doors to be removed. Any of the enclosure panels may be removed by opening the latch and lifting it
up slightly.
DANGER
Do not operate the compressor with the fan and belt guard removed. Exposed
fan and belts may cause injury to personnel.
CAUTION
The enclosure doors and panels must be closed and latched while the
compressor is operating. Failure to close and latch the doors and panels will
cause high temperature shutdowns.
Figure 2-3 – COLD WEATHER INSTALLATION

13-8-620 Page 10
INSTALLATION FOR COLD WEATHER OPERATION (Figure 2-3, page 9) - It is recommended that the
unit be installed inside a shelter that will be heated to temperatures above freezing (32o F, 0o C). This will
eliminate many of the problems associated with operating units in cold climates, such as freezing in
control lines and downstream of the cooler.
Refer to Engineering Data Sheet 13-9-411 for the advantages of using the heat recovered from rotary
compressors. This heat recovery could easily pay for an adequate shelter for the unit.
When an outside installation must be made, the precautions required will depend on the severity of the
environment. The following are general guidelines for outside installations:
Cold Weather (Down To +10o F)
1. Be sure all drains, traps, and control lines, including pressure transducer lines are heated to avoid
freezing of condensate. Heat tape with thermostat control is generally satisfactory for this purpose
and can be obtained at various local plumbing or hardware outlets at nominal cost.
2. Provisions to bypass the aftercooler must be made. Since cold air contains very little moisture,
successful operation can be achieved without the aftercooler.
3. Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow.
4. Use only Champion RotorLub 8000 lubricant.
5. Monitor unit carefully during start-up and operation to be sure it is functioning normally.
Remember unsheltered (outside) installations should be avoided where possible. Installation next to a
heated building where enough heat can be used to keep the compressor room above freezing will save
many complications in the operation and installation of the unit.
AUXILIARY AIR RECEIVER - An auxiliary air receiver is not required if the piping system is large and
provides sufficient storage capacity to prevent rapid cycling. When used, an air receiver should be of
adequate size, provided with a relief valve of proper setting, a pressure gauge and a means of draining
condensate
OPTIONAL MOISTURE SEPARATOR/TRAP - The unit is equipped with a built-in aftercooler, a
combination moisture separator and trap is furnished as an option to the unit. This should be piped into
the system down stream of the aftercooler.
CONTROL PIPING - Control piping is not necessary since the rotary screw unit is factory wired and piped
for the control system specified.
INLET LINE - Where an inlet line is used between the air filter and the compressor, it must be thoroughly
cleaned on the inside to prevent dirt or scale from entering the compressor. If welded construction is
used, the line must be shot blasted and cleaned to remove welding scale. In either case, the inlet line
must be coated internally by galvanizing or painting with a moisture and oil-proof sealing lacquer. Up to
ten (10) feet in length, the inlet line should be the full size of the inlet opening on the compressor. If an
extra-long line is necessary, the pipe size should be increased according to “Inlet Line Length Chart”
below.
Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a
remote location.

13-8-620 Page 11
INLET LINE LENGTHS
Length of Inlet Line Diameter of Pipe Size
0 to 10 Feet............................................. Same as Compressor Inlet Opening
10 to 17 Feet........................................... One Size Larger Than Inlet Opening
17 to 38 Feet........................................... Two Sizes Larger Than Inlet Opening
DISCHARGE SERVICE LINE - The discharge service line connection is made at the right hand corner of
the package when viewed from the control box end, viewed from the oil cooler side. A hand operated
valve, (air service valve) must be installed between the unit and the customer’s air system. If a fast
operating valve such as a ball valve is used, it must be closed slowly to give the intake valve time to shut
and keep the discharge pressure from spiking. When manifolding two or more rotary screw units on the
same line, each unit is isolated by the check valve in the unit discharge line. If a rotary screw unit is
manifolded to another compressor, be sure the other compressor has a check valve in the line between
the machine and the manifold. If a rotary screw and a reciprocating compressor are manifolded together,
an air receiver must be located between the two units.
DANGER
Discharge air used for breathing will cause severe injury or death.
Consult filtration specialists for additional filtration and treatment equipment to
meet health and safety standards.
ELECTRICAL WIRING - All of the electrical connections and controls are factory wired for the voltage
specified on the order. Verify that the available voltage source matches that shown on the compressor
package nameplate before installing the compressor package. It is necessary only to connect the
package to the supply and ground of the branch circuit. The connections to the compressor package are
made with the electrical controls box, accessible by opening the cover of the box.
The 24CA4820 Control Transformer (Cutler-Hammer C0250G6U) is connectable for a variety of input
voltages. Ensure that it is properly connected prior to applying power to the package. Recommended
connections are:
Line Voltage Primary Connect Secondary Connect
200-208 H1 & H2 X1 & X4
230-240 H1 & H2 X1 & X3
380-416 H1 & H3 X1 & X3
460-480 H1 & H4 X1 & X3
575-600 H1 & H5 X1 & X3
WARNING
Electrical shock can cause injury or death. Open main disconnect switch,
lockout and tagout before working on control box.

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GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical
Code.
WARNING
Failure to properly ground the compressor package could result in injury or
death. Install ground wiring in accordance with the National Electrical Code
and any applicable local codes.
MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure
on proper lubrication of the bearings. The following charts show recommended grease qualities and
regreasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s
instructions.
The following procedure should be used in regreasing:
1. Stop the unit.
2. Disconnect, lockout and tagout the unit from the power supply.
3. Remove the relief plug and free hole of hardened grease.
4. Wipe lubrication fitting clean and add grease with a hand-operated grease gun.
5. Leave the relief plug temporarily off. Reconnect unit and run for about 20 minutes to expel the
excess grease.
6. Stop the unit. Replace the relief plug.
7. Restart the unit.
WARNING
Rotating machinery can cause injury or death. Open main disconnect, lockout
and tagout power supply to starter before working on the electric motor.

13-8-620 Page 13
ELECTRIC MOTOR GREASE RECOMMENDATIONS (-30°TO 50°C)
MANUFACTURER TRADE NAME
CHEVRON SRI #2
SHELL DOLIUM R
EXXON UNIREX #2
EXXON POLYREX
ELECTRIC MOTOR REGREASING INTERVAL
Type of
Service Typical Rating Relubrication Interval
Up to 150 HP (112 KW) 18 Months
Standard One or Two Shift Operation Above 150 HP (112 KW) 12 Months
Up to 150 HP (112 KW) 9 Months
Severe Continuous Operation Above 150 HP (112 KW) 6 Months
Up to 150 HP (112 KW) 4 Months
Very Severe Dirty Locations, High Ambient
Temperature Above 150 HP (112 KW) 2 Months