Champion CCE10, CCE30, CVE50, CCE20 Operation Maintenance Manual & Parts List

OPERATION MAINTENANCE

MANUAL & PARTS LIST

SINGLE STAGE ONE AND TWO CYLINDER OIL-LESS

AIR COMPRESSORS, 3/4 THROUGH 5 HP

THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD ALWAYS BE

AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT.

READ, UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS

EQUIPMENT TO PREVENT INJURY OR EQUIPMENT DAMAGE.

Form No. F3266 VER: 12 07/01/2009

B998-A
(Ref. Drawing)

MODEL H3MTOIl - 6

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.

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 North Euclid Avenue
Princeton, IL 61356

Phone: [phone]

Fax: [phone]
E-Mail: Champion@Champion pneumatic . com

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.

2

TABLE OF CONTENTS

________________________________________________________

Subject Page

Maintain Compressor Reliability And Performance With .................................................. 2

Explanation Of Safety Instructions Symbols And Decals.................................................. 4

Safety And Operation Precautions.................................................................................... 5

Introduction........................................................................................................................ 6

Warranty ............................................................................................................................ 6

Specifications .................................................................................................................... 7

Installation ......................................................................................................................... 8

Operation................................................................................................................. 11 & 12

Maintenance......................................................................................................13, 14 & 15

Compressor Pilot Valve Differential Pressure Adjustment.............................................. 16

Parts Replacement Schedule..................................................................................17 & 18

Trouble Shooting Chart ...........................................................................................19 & 20

Unit Repair Parts List ..........................................................................................21 thru 26

Unit Hazard Decal Listing........................................................................................27 & 28

Pump Hazard Decals ...................................................................................................... 29

Record Of Maintenance Service .............................................................................30 & 31

3

EXPLANATION OF SAFETY INSTRUCTIONS SYMBOLS AND DECALS

DANGER

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

WARNING

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

CAUTION

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.

DANGER

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.

WARNING

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.
Nonapproved uses will also void warranty.

CAUTION

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.

4

SAFETY AND OPERATION PRECAUTIONS

___________________________________________________________________________________

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

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

2. For installation, follow all local electrical and safety codes, as well as the National Electrical Code
(NEC) and the Occupational Safety and Health Act (OSHA).

3. Electric motors must be securely and adequately grounded. This can be accomplished by wiring
with a grounded, metal-clad raceway system to the starter; by using a separate ground wire
connected to the bare metal of the motor frame; or other suitable means.

4. Protect the power cable from coming in contact with sharp objects. Do not kink power cable and
never allow the cable to come in contact with oil, grease, hot surfaces, or chemicals.

5. Make certain that the power source conforms to the requirements of your equipment.

6. Pull main electrical disconnect switch and disconnect any separate control lines, if used, before
attempting to work or perform maintenance on the air compressor or unit. "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 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 or rags or loose parts are left on the compressor or drive parts.

13. Do not use flammable solvents for cleaning the air inlet filter or element and other parts.

14. Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts by
covering parts and exposed openings with clean cloth or Kraft paper.

15. Do not operate the compressor without guards, shields and screens in place.

16. Do not install a shut-off valve in the discharge line, unless a pressure relief valve, of proper design
and size, is installed in the line between the compressor unit and shut-off valve.

17. Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic
fumes.

18. Be careful when touching the exterior of a recently run motor - it may be hot enough to be painful
or cause injury. With modern motors this condition is normal if operated at rated load - modern
motors are built to operate at higher temperatures.

19. Inspect unit daily to observe and correct any unsafe operating conditions found.

20. Do not "play around" with compressed air, nor direct air stream at body, because this can cause
injuries.

21. Compressed air from this machine absolutely must not be used for food processing or breathing
air without adequate downstream filters, purifiers and controls.

22. Always use an air pressure regulating device at the point of use, and 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 blowgun.

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.

5

INTRODUCTION

Champion Oil-Less 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.

Express Limited Warranty

CHAMPION warrants each new piece of equipment manufactured by CHAMPION to be free from

defects in material and workmanship under normal use and service for a period of twelve (12) months
from date of installation or eighteen (18) months from date of shipment by CHAMPION or CHAMPION
authorized distributor, whichever may occur first.

CHAMPION makes no warranty in respect to components and accessories furnished to CHAMPION by
third parties, such as ELECTRIC MOTORS, and CONTROLS, which are warranted only to the extent of
the original manufacturer's warranty to CHAMPION. To have warranty consideration, electric motors
must be equipped with thermal overload protection.

When a compressor pump, or component is changed or replaced during the warranty period, the newly
replaced item is warranted for only the remainder of the original warranty period.

Repair, replacement or refund in the manner and within the time provided shall constitute CHAMPION'S
sole liability and your exclusive remedy resulting from any nonconformity or defect. CHAMPION SHALL
NOT IN ANY EVENT BE LIABLE FOR ANY DAMAGES, WHETHER BASED ON CONTRACT,
WARRANTY, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE, INCLUDING WITHOUT
LIMITATION ANY CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES, ARISING WITH
RESPECT TO THE EQUIPMENT OR ITS FAILURE TO OPERATE EVEN IF CHAMPION HAS BEEN
ADVISED OF THE POSSIBILITY THEREOF.

CHAMPION MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND, EXCEPT THAT
OF TITLE, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY EXPRESSLY
DISCLAIMED. NO SALESMAN OR OTHER REPRESENTATIVE OF CHAMPION HAS AUTHORITY TO
MAKE ANY WARRANTIES.

6

COMPRESSOR UNIT SPECIFICATIONS

COMPRESSOR

MODEL

CCE10 3/4 430 3.7 100 450 2100

CCE10 1 575 4.9 100 600 2800

CCE20 1½ 570 9.6 100 1315 3360

CCE20 2 680 11.5 100 1570 4480

CCE30 3 650 17.1 100 1500 6700

CVE50 5 650 27.4 100 1500 12,000

MOTOR

H.P.

PUMP

RPM

DISPL
(CFM)

MAXIMUM

PRESSURE (PSIG)

Minimum Ambient Temperature 32°F

Maximum Ambient Temperature 100°F

COOLING

AIR FLOW

(CFM)

HEAT

REJECTION

(BTU/HR)

7

INSTALLATION

WARNING

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

1. Permanently installed compressors must be located in a clean, well ventilated dry room so

compressor receives adequate supply of fresh, clean, cool and dry air. It is recommended that a
compressor, used for painting, be located in a separate room from that area wherein body sanding
and painting is done. Abrasive particles or paint found to have clogged the air intake filters and
intake valves shall automatically void warranty.

2. Compressors should never be located so close to a wall or other obstruction that flow of air through

the cooling fan, which cools the compressor, is impeded. Permanently mounted units should have
cooling fan at least 12" from wall.

3. Place stationary compressors on firm level ground or flooring. Permanent installations require

bolting to floor. Bolt holes in tank or base feet are provided. Before bolting or lagging down, shim
compressor level to avoid putting a stress on a tank foot. It is recommended that unit be set on
optional vibro-isolator pads. Tanks bolted directly to a concrete floor without isolators will not be
warranted against cracking.

4. If installing a base mounted unit, make certain pressure limiting controls are properly installed and

operational. A pressure switch is required for start/stop control. Units furnished with dual control
are supplied with a pilot valve. The pilot valve requires a control air pressure line from the air
receiver to be connected to the pilot valve.

DANGER

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

DANGER

Factory assembled medical units equipped with an isolation valve have a pressure relief valve
installed in the discharge line between the compressor and isolation valve. Do not remove or
adjust.

WARNING

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

CAUTION

• Do not install an area where ambient temperature is below 32 degrees F. or above
100 degrees F.

• Do not install unit in an area where air is dirty and/or chemical laden.

• Unit is not to be installed outdoors.

8

INSTALLATION (CONT’D)

ELECTRICAL POWER SUPPLY

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

All wiring should be performed by a licensed electrician or electrical contractor. Wiring must meet
applicable codes for area of installation. The table gives recommended wire sizes based on the
1999 NEC.

WIRE SIZE (AWG)

COPPER CONDUCTOR - 75°C TEMP. RATING - 30° AMBIENT

MOTOR

HP

200/208V 230V 460V 575V 115V 208V 230V

3/4 – 1-1/2 14 (14) 14 (14) 14 (14) 14 (14) 10 ( 8) 14 (10) 14 (12)
2 14 (12) 14 (12) 14 (14) 14 (14) 8 ( 6) 12 ( 8) 12 (10)
3 14 (10) 14 (12) 14 (14) 14 (14) 8 ( 4) 10 ( 8) 10 ( 8)
5 10 ( 8) 12 ( 8) 14 (12) 14 (12) ----- 8 ( 6) 8 ( 6)

Valves in ( ) for duplex unit with one incoming power line to both motors.

All models require a properly sized magnetic starter as specified in the National Electric Code (NEC).
See Figure 1-1 for simplex wiring diagram and Figure 1-2 for duplex wiring diagram.

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

3 PHASE 1 PHASE

300CHS546-A
(Ref. Drawing)

Figure 1-1 Simplex Wiring Diagram

9

301CHS546-A
(Ref. Drawing)

INSTALLATION (CONT’D)

300CHD546-A
(Ref. Drawing)

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

Figure 1-2 Duplex Wiring Diagram

CAUTION

10

301CHD546-A
(Ref. Drawing)