R-SERIES
R-10/15
R-30 R-40R-
70
THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD ALWAYS
Air Compressors and Units
OPERATION & SERVICE MANUAL
Electric Drive Compressors & Units
BE AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT. READ, UNDERSTAND
AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT TO PREVENT
INJURY OR EQUIPMENT DAMAGE.
CQF3473 v.01 April 17, 2018
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE CHAMPION® COMPRESSOR
PARTS AND SUPPORT SERVICES
Champion® Compressor genuine parts, manufactured to design tolerances, are developed for
optimum dependability – specifically for Champion compressor systems. Design and material
innovations are the result of years of experience with hundreds of different compressor
applications. Reliability in materials and quality assurance are incorporated in our genuine
replacement parts.
Your authorized Champion Compressor distributor offers all the backup you’ll need. A
worldwide network of authorized distributors provides the finest product support in the air
compressor industry. Your authorized distributor can support your Champion air compressor
with these services:
1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. A full line of factory tested CHAMPLUB™ compressor lubricants specifically formulated
for use in Champion compressors.
3. Repair and maintenance kits designed with the necessary parts to simplify servicing your
compressor.
Authorized distributor service technicians are factory trained and skilled in compressor
maintenance and repair. They are ready to respond and assist you by providing fast, expert
maintenance and repair services.
To Contact Champion or locate your local distributor:
Visit: www.championpneumatic.com
Or
Call: (888)436-5499
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, HORSEPOWER and SERIAL NUMBER
(see nameplate on unit). All orders for Parts should be placed with the nearest authorized
distributor.
Order by part number and description. Reference numbers are for your convenience only.
-Series Electric 2 CQF3473 v.01
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Table of Contents
Introduction ............................................................................................................................................ 4
Safety and Operation Precautions ........................................................................................................... 4
Explanation of Safety Instructions, Symbols, and Decals .......................................................................... 6
Safety and Operation Precautions ........................................................................................................... 6
Unit Hazard Decal List – See Page 8 ......................................................................................................... 7
Pump Hazard Decal List – See Page 9 ....................................................................................................... 7
Unit Hazard Decals .................................................................................................................................. 8
Pump Hazard Decals ................................................................................................................................ 9
Installation ............................................................................................................................................ 10
Air Receiver Installation ......................................................................................................................... 13
Operation .............................................................................................................................................. 14
Low Oil Shutdown Control ..................................................................................................................... 16
Compressor Oil Specifications................................................................................................................ 18
Guide to Maintenance ........................................................................................................................... 20
Maintenance Checklist .......................................................................................................................... 26
Troubleshooting Chart ........................................................................................................................... 27
Maintenance Log ................................................................................................................................... 29
-Series Electric 3 CQF3473 v.01
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Operation & Service April 17, 2018
Introduction
Champion R Series 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.
Standard Warranty
R Series Compressor Packages
STANDARD WARRANTY
Champion (the “Company”) warrants to each original 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. This Standard
Warranty statement applies to compressors shipped after April 1
st
, 2018.
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 recommended to maintain warranty. 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
Package
Pump – Package
Pump – Bare
Electric Motors
Air Receivers
12 months from startup or 18 months from date of
shipment from Company, whichever occurs first
24 months from startup or 30 months from date of
shipment from Company, whichever occurs first
12 months from startup or 18 months from date of
shipment from Company, whichever occurs first
12 months from startup or 18 months from date of
shipment from Company, whichever occurs first
12 months from startup or 18 months from date of
shipment from Company, whichever occurs first
All components within the package (ie pressure switch, starter, etc),
excluding normal wear items
Applies to pump only, excludes head valves which are warranted for first
year only.
Applies to pumps purchased as bares only
For nonstandard motors, the original manufacturer’s warranty will take
precedence
Recommended to be installed properly with Company vibration isolators
Service will be provided by Company representative or authorized service
personnel, for repair or replacement of any product or part which in the
Labor
Package/Electric Motor/Air Receivers/Bare
Pumps: 12 months from startup or 18 months from
date of shipment from Company, whichever occurs
first
Pump (Package): 24 months from startup or 30
months from date of shipment from Company,
whichever occurs first
Company’s sole judgement is proved not to be as warranted. Labor shall be
limited to the amount specified in the Company’s labor rate schedule. All
costs of transportation of product, parts, and repaired or replacement parts
claimed not to be as warranted to and from such service facilities shall be
borne by the Purchaser. The Company may require the return of any part
claimed not to be as warranted to one of its facilities as designated by
Company, to establish a claim under this warranty (Return freight eligible for
consideration for reimbursement). Replacement Parts provided under the
terms of the warranty are warranted for the remainder of the original
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 sole judgement, as to affect the product adversely
2. Any product which has, in the Company’s sole judgement 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
5. Warranty is non-transferable
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.
R-Series Electric 4 CQF3473 v.01
Operation & Service April 17, 2018
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) an
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 bar
etal of the motor frame or other suitable means.
m
4. Protect the power cable from coming in contact with sharp objects. Do not kink power cable and never allow
the
cable to come in contact with oil, grease, hot surfaces, or chemicals.
5. Make certain that the power source conforms to the requirements of your equipment.
6. Pull main electrical disconnect switch and disconnect any separate control lines, if used, before attempting to
work or perform maintenance on the air compressor or unit. "Lock out" or "Tag out" all power sources.
7. Do not attempt to remove any compressor parts without first relieving the entire system of pressure.
8. Do not attempt to service any part while machine is in an operational mode.
9. Do not operate the compressor at pressures in excess of its rating.
10. Do not operate compressor at speeds in excess of its rating.
11. Periodically check all safety devices for proper operation. Do not change pressure setting or restric
ation in any way.
oper
12. Be sure no tools, rags, or loose parts are left on the compressor or drive parts.
13. Do not use flammable solvents for cleaning the air inlet filter or element and other parts.
14. Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts by covering
parts and exposed openings with clean cloth or Kraft paper.
15. Do not operate the compressor without guards, shields and screens in place.
16. Do not install a shut-off valve in the discharge line, unless a pressure relief valve, of proper design and size, is
installed in the line between the compressor unit and shut-off valve.
17. Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic fumes.
18. Be careful when touching the exterior of a recently run motor - it may be hot enough to be painful or cause
injury. With modern motors this condition is normal if operated at rated load - modern motors are built to
operate at higher temperatures.
19. Inspect unit daily to observe and correct any unsafe operating conditions found.
20. Do not "play around" with compressed air nor direct air stream at body. This can cause injuries.
21. Compressed air from this machine absolutely must not be used for food processing or breathing air withou
adequate
22. Always use an air pressure regulating device at the point of use. Do not use air pressure greater than marked
maximum pressure of attachment.
23. Check hoses for weak or worn condition before each use and make certain that all connections are secure.
24. Always wear safety glasses when using compressed air gun.
downstream filters, purifiers and controls.
d
e
t
t
The user of any air compressor package manufactured by Champion – A Gardner Denver Co., is hereby warned
that failure to follow the preceding Safety and Operation Precautions can result in injuries or equipment damage.
However, Champion – A Gardner Denver Co., does not state as fact or does not mean to imply that the preceding
list of Safety and Operating Precautions is all inclusive, and further that the observance of this list will prevent all
injuries or equipment damage.
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Explanation of Safety Instructions, Symbols, and Decals
Indicates immediate
hazards which will result in severe injury or death.
Indicates hazards or unsafe practice which could result in severe injury or death.
Indicates hazards or unsafe practice which could result in damage to the Champion compressor or
Notice is used to notify people of installation, operation, or maintenance information which is
OBSERVE, UNDERSTAND, AND RETAIN THE INFORMATION GIVEN IN THE SAFETY PRECAUTION
This Oil
-
Lubricated
Compressor must not be used for breathing air without adequate downstream
The use of this compressor as a booster
pump and/or to compress a medium other than
This unit may be equipped with special options which may not be included
in this manual. User
minor injury.
NOTICE
important but not hazard related.
Safety and Operation Precautions
DECALS AS SHOWN IN THE DECAL LIST SECTION.
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.
atmospheric air is strictly non-approved and can result in equipment damage and/or injury. Nonapproved uses will also void warranty.
must read, understand, and retain all information sent with special options.
R-Series Electric 6 CQF3473 v.01
Operation & Service April 17, 2018
Unit Hazard Decal List – See Page 8
PART NO.
DESCRIPTION
P10157A
PRODUCT LIABILITY DECAL SHEET
- MASTER
1
Unit Pressure Setting
2
NOT USED
3
DANGER
–
Breathing Air
4
DANGER
– Drain Tank Daily
5
WARNING
– Pressure/Safety Valve
6
NOT USED
7
DANGER
– Valve Maintenance
8
DANGER
– High Voltage
9
WARNING
– Hot Surfaces
10
WARNING
– Do Not Remove Fan Guard
11a NOTICE
- Lubricant
11b NOT
USED
12
DECAL
– Synthetic or Food Grade Inserts
13
NOT USED
14
DECAL
– Pressure Setting: 95
-
125 PSIG
14
DECAL
– Pressure Setting: 140
-
175 PSIG
15
NOTICE
– Read and Retain Manuals
16
NOT USED
17
DECAL
– Rotation Direction
18
NOT USED
P14677A
DECAL
– Pressure Switch
PART NO.
DESCRIPTION
P13805A
PUMP DECAL SHEET
– MASTER
A1
NOT USED
A2
NOTICE
- Lubricants
B
DECAL
– Rotation Direction
C
NOTICE
– Read and Retain Manuals
D
DANGER
– Breathing Air
E
DECAL
– Made in the United States of America
F
IMPORTANT NOTICE
– Motor Burn
-
Outs
P14677A
Pump Hazard Decal List – See Page 9
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Unit Hazard Decals
R-Series Electric 8 CQF3473 v.01
Operation & Service April 17, 2018
Pump Hazard Decals
F
R-Series Electric 9 CQF3473 v.01
Operation & Service April 17, 2018
Installation
D
o not tighten the
anchor
screws/nuts down completely
– this will result in undesirable stress on
Do not operate unit if damaged during shipping, handling or use. Operating unit if damaged may
result in injury.
. Permanently installed compressors must be located in a clean, well ventilated dry room
1
ompressor receives adequate supply of fresh, clean, cool, and dry air. It is recommended that
c
c
ompressor, 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
intake valves, shall automatically void warranty.
2. Compressors should never be located so close to a wall or other obstruction that flow of air throug
he fan-bladed flywheel, which cools the compressor, is impeded. Permanently mounted unit
t
shoul
d be installed so that the belt guard is at least 12" from wall.
3. Place stationary compressors on firm level ground or flooring. Permanent installations are requi
to be anchored to floor. Bolt holes are provided in the air receiver or base feet. Use shims to level
the compressor unit. It is recommended that optional vibration isolator pads be installed with the
unit. Tanks anchored directly to a concrete floor without vibration isolator pads will not
warrant
to apply to ASME air receivers. See “Air Receiver Installation” section.
ed against cracking. Champion vibration isolator pads must be used for extended warranty
so
a
and
s
red
be
h
the tank foot. This can cause abnormal vibration and possible cracking of the air receiver, resulting
in injury or equipment damage.
. If installing a bare pump or a base-mounted unit, make certain the system has adequate
4
imiting controls. Controls could be a pressure switch for start/stop operation or a pilot valve
l
c
ontinuous operation. If a pilot valve is used, the compressor must be equipped with
oaders. Control air must be piped from the air receiver to the pilot valve.
unl
5. A properly sized air check valve must be installed in the discharge piping, between the c
out
let and the inlet of any receiver tank(s) in the system.
Do not install isolating valves between compressor outlet and air receiver. This will cause excessive
pressure if valve is closed, and cause injury and equipment damage.
pressure
for
head
ompressor
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Installation (continued)
●
Do not install in an area
where ambient temperature is below 32
°
F or above 10
4°
F.
3 PHASE
1 PHASE
200/208V
230V
460V
575V
115V
208V
230V
2
14 (1
2)
14 (1
2)
14 (14)
14 (14)
8 (4) 12 (8) 12 (10)
3 12 (10) 14 (1
0)
14 (14)
14 (14)
6 (3)
10 (6) 10 (8)
5
10 (6) 12 (8)
14 (12)
14 (12)
--
8 (4) 8 (4) 7-1/2
8 (4) 10 (6)
14 (10)
14 (10)
-- 4 (1)
6 (2) 10 8 (3) 8 (4)
12 (8)
14 (10)
-- -- -- 15 4 (1)
6 (2) 10 (6)
10 (6
) -- -- -- 20 3 (00) 4 (0) 8 (4) 10 (6)
-- -- -- 25
1 (00
00)
2 (000) 6 (3) 8 (4) -- -- -- 30 0 (
250)
1 (0000) 6 (2) 8 (4)
-- -- --
Always use an air pressure regulating device at the point of use. Failure to do so can result in injury
or equipment damage.
● Do not install unit in an area where air is dirty and/or chemical laden.
● Unit is not to be installed outdoors.
LECTRICAL POWER SUPPLY
E
It is essential that the power supply and the supply wiring are adequately sized and that the voltage
corresponds to the unit specifications. Branch circuit protection must be provided at installation as
specified in the National Electrical Code.
All wiring should be performed by a licensed electrician or electrical contractor. Wiring must meet
applicable codes for area of installation. The table gives recommended wire sizes based on the 2017
NEC.
WIRE SIZE (AWG) - 75°C COPPER - 40°C AMBIENT
MOTOR
HP
ues in ( ) for Duplex Unit w/one incoming power line to both motors.
Val
All models require a properly sized magnetic starter as specified in the National Electric Code (NEC).
See Control Panel Manual for details.
If ordered with a factory mounted control panel, compressor is wired at factory. It is necessary only to
bring lines from a properly sized disconnect switch to the control panel mounted on the unit.
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Installation (continued)
Wiring must be such that when viewing compressor from opposite shaft end, rotation of shaft is
MODEL
25’ 50’ 100’ 200’ 300’ R10D
3/4” (1”) 3/4” (1”) 3/4” (1”) 3/4” (1”) 3/4” (1”) R15B
3/4” (1”) 3/4” (1”) 3/4” (1”) 1” (1-1/4”)
1” (1-
1/4”)
R30D
3/4” (1-1/4”)
1” (1-
1/4”)
1” (1-
1/4”)
1” (1-
1/2”)
1” (1-
1/2”)
R40A
1-
1/4” (1-1/2”)
1-1/4” (1-1/2”)
1-1/4” (1-1/2”)
1-1/4 (1-1/2”)
1-1/4” (1-1/2”)
R70A
1-
1/4” (1-1/2”)
1-1/4” (1-1/2”)
1-1/4” (1-1/2”)
1-1/2”
(2”) 1-1/2”
(2”)
clockwise as shown by arrow on guard. Wrong direction rotation for any length of time will result
in damage to compressor.
GROUNDI
NG INSTRUCTIONS
This product should be connected to a grounded, metallic, permanent wiring system, or an equipmentgrounding terminal or lead on the product.
AIR LINE PIPING
C
onnection to air system should be of the same size, or larger, than discharge pipe out of unit. The table
gives recommended minimum pipe sizes. A union connection to the unit and water drop leg is
recommended. Install a flexible connector between the discharge of the unit and the plant air piping.
Plant air piping should be periodically inspected for leaks using a soap and water solution for detection
on all pipe joints. Air leaks waste energy and are expensive.
Minimum Pipe Sizes For Compressor Air Lines
(Based on clean Smooth Schedule 40 Pipe)
ues in ( ) are for duplex unit.
Val
Never use plastic pipe or improperly rated metal pipe. Improper piping material can burst and cause
injury or property damage.
-Series Electric 12 CQF3473 v.01
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Air Receiver Installation
D
o not tighten the
anchor
screws/nuts down completely
– this will result in undesirable stress on
TEN011442
-00
CUT-AWAY VIEW OF
bration isolator pads can be purchased from your local authorized distributor. Installation hardware
Vi
items (studs, screws, nuts, shims) are not provided. It is the compressor owner’s responsibility to
provide a suitable foundation and isolator installation.
the tank foot. This can cause abnormal vibration and possible cracking of the air receiver, resulting
in injury or equipment damage.
(Ref. Drawing)
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ANCHORED
INSTALLATION
Operation
This compressor has been inspected, thoroughly tested and approved at the factory. For this unit to
give long satisfactory service it must be installed and operated properly. This compressor has been
designed for an 80%/ON – 20%/OFF duty cycle.
SIMPLEX UNITS have a pressure switch that senses changes in receiver pressure and automatically starts
and stops the compressor at preset pressure limits. If the receiver pressure falls below the cut-in
pressure setting of the pressure switch the compressor will run until the cut-out pressure setting of the
pressure switch has been reached.
DUPLEX UNITS have lead (PS1) and lag (PS2) pressure switches and an automatic alternating system to
evenly distribute the load between the two compressors. The pressure switches sense changes in
receiver pressure and automatically start and stop the compressor at preset pressure levels. If the
receiver pressure falls below the cut-in pressure setting of the lead (PS1) pressure switch but remains
above the cut-in pressure setting of the lag (PS2) pressure switch, only one compressor will run until
receiver pressure reaches the cut-out pressure of the lead (PS1) pressure switch. The next time the
pressure in the receiver drops, the system automatically starts the compressor that was idle. If the
receiver pressure falls below the cut-in pressure setting of the lag (PS2) pressure switch, both
compressors run until receiver pressure reaches the cut-out pressure setting of the lead (PS1) pressure
switch.
CONTINUOUS RUN units are equipped with a ball valve, pilot valve and head unloaders to provide
continuous run capabilities. The pilot valve acts as an automatic air switch allowing air to flow from the
receiver to the head unloader mechanism, thus actuating it. To operate unit in continuous run, open
ball valve located next to pilot valve. The pilot valve is now able to sense receiver pressure. When the
receiver pressure reaches the cut-out pressure setting of the pilot valve, the pilot valve opens and air is
released to the unloader mechanism. The compressor stops compressing air and runs unloaded until
the cut-in pressure setting of the pilot valve has been reached. At this time air released from the
unloader mechanism and the compressor starts compressing again. Continuous run is recommended if
motor starts exceed 8 starts/hour.
INITIAL START UP – ELECTRIC MOTOR UNITS
1. Inspect unit for any visible signs of damage that would have occurred in shipment or during
installation.
2. Pull main disconnect switch to unit to assure that no power is coming into the unit. “Lock Out”
“T
ag Out” switch. Connect power leads to start.
Do not attempt to operate compressor on voltage other than that specified on order or on
compressor motor and control panel. Voltage conversion kits are available if alternate operating
voltage is required.
or
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Operation (continued)
3. Check compressor oil level. Add oil as required. See “Compressor Oil Specifications” Section.
NOTE: Do not mix oil type, weights, or brands.
4. Activate main disconnect switch.
5. “Jog” motor and check for proper rotation by direction arrow. If rotation is wrong, reverse input
connections on the magnetic starter.
6. Close receiver discharge ball valve and start the compressor.
7. With receiver ball valve closed, let the machine pump up to operating pressure.
8. Check for proper operation of the pressure switch.
a. When the air receiver pressure reaches the cut-out setting of the pressure switch, t
mac
hine will stop.
b. Open the receiver ball valve slowly, allowing pressure in the receiver to drop.
c. When the air receiver pressure drops to the cut-in setting of the pressure switch, t
mac
hine will start.
d. Repeat steps a. thru c. three times.
he
he
9. Check for proper operation of the head unloaders (if equipped).
a. Open the ball valve located next to the pilot valve.
b. When the air receiver pressure reaches the cut-in setting of the pilot valve, the
unloaders will activate. The air compressor continues to run, but air compression is stopped.
c. Open the receiver ball valve slowly, allowing pressure in the receiver to drop.
d. When the air receiver pressure drops to the cut-out setting of the pilot valve, the head
unloaders will de-activate. Air compression will resume.
e. Repeat steps b. thru d. three times.
10. Check for proper operation of any options.
11. When the initial run period has shown no operating problems, shut unit down and recheck oil level.
12. Open receiver ball valve. The air compressor unit is now ready for use.
This unit can start automatically without warning.
head
-Series Electric 15 CQF3473 v.01
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Low Oil Shutdown Control
C509-A
343CAS546
(optional equipment)
The oil monitor must be used in conjunction with a magnetic starter (see wiring diagram for details).
The oil monitor is installed on the outside of the air compressor crankcase with a port that allows oil
to feed into it’s float bowl chamber and maintain the same level as in the crankcase. The float moves
vertically up or down as the oil level changes. If the oil level is below minimum allowable operating
level, the reed switch will open, thus stopping the motor. A magnet holds the float and prevents the
compressor from starting. In order to start the compressor the following steps must be taken:
1. Fill crankcase to recommended capacity as indicated when level reaches the middle of the oil
sight glass.
2. Turn cam reset knob 90° clockwise.
IMPORTANT NOTE: The Oil Monitor does not eliminate the compressor owner's responsibility for
periodically checking oil level. Refer to maintenance instructions.
(Ref. Drawing)
WIRING DIAGRAM: The oil monitor is wired into the control panel as shown below. Refer to the
Control Panel User Manual for complete wiring diagrams.
(Ref. Drawing)
Remove jumper between 5 & 6
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Operation & Service April 17, 2018
Low Oil Shutdown Control (continued)
(optional equipment)
TROUBLESHOOTING & SERVICING
Always disconnect unit from power supply and relieve all pressure from air tank before
performing any maintenance. “Lock Out” or “Tag Out” all power sources. Failure to do so
may result in personal injury or death.
NOTICE
Do not disassemble LOSC switch. Disassembly will void warranty.
o adjustments are required for the oil monitor.
N
If the oil monitor does not operate properly, check the items listed below to determine the cause.
1. Crankcase Oil
a. Check sight glass to insure proper oil level in crankcase, when compressor is shut off.
b. Check crankcase oil for proper viscosity. This is particularly important for temperat
c. Change oil regularly. Clean oil insures proper operation of the Oil Monitor, as well
2. Vent T
a. C
b. Check the gasket between valve body and bowl for leaks. This will cause a pressure rise i
c. Check the fittings at ends of vent tube for tightness and leaks.
Reset
3.
a. C
b. Verify that reset knob is in fully counterclockwise position.
c
onditions below 32˚F. Oil which is too thick can slow the response of the mechanism,
causing float to register a low level.
ompressor. See Compressor Oil Specification and Maintenance sections for details.
c
ube
heck vent tube to insure it is not clogged.
t
he crankcase which will give a false safe oil level indication.
heck that reset return spring is in proper working order.
ure
as
n
-Series Electric 17 CQF3473 v.01
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Operation & Service April 17, 2018
Compressor Oil Specifications
CHAMPLUB
ISO 100
DESCRIPTION
PART NUMBER
1 – Quart Case (12/case)
P09479A
1 – Gallon Case (4/case)
P08909A
5 – Gallon Pail
P08908A
55 –
Gallon Drum
P08907A
CHAMPLUB
SYNTHETIC
DESCRIPTION
PART NUMBER
1 – Quart Case (12/case)
P13179A
1 – Gallon Case (4/case)
P13180A
5 – Gallon Pail
P11506A
55 –
Gallon Drum
P13181A
ompressors are factory filled with CHAMPLUB hydrocarbon-based recip lubricant. This is an ISO 100
C
non-detergent industrial lubricant with rust and oxidation inhibitors specially formulated for
reciprocating compressors. It is recommended this compressor be maintained using this oil for ambient
temperatures above 32°F.
CHAMPLUB synthetic is a premium grade diester based synthetic lubricant providing excellent
performance in high temperature applications.
Do not mix oil types, weights or brands.
Emulsification of oil (white milky substance) indicates unsafe accumulation of moisture and may
be evidence compressor is oversized for application. Failure to promptly consult your local
distributor, or Champion Customer Service, can be grounds to deny warranty.
L
UBRICANT - ISO 100 MINERAL
LUBRICANT - SYNTHETIC DIESTER
-Series Electric 18 CQF3473 v.01
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Operation & Service April 17, 2018
Compressor Oil Specifications (continued)
Maintain lubricant level
LUBRICANT LEVEL:
at center of sight glass
BREAK-IN PERIOD: 100 hours of operation or 3 months, whichever comes first.
1. Compressor must run for the break-in period using CHAMPLUB ISO 100 lubricant.
2. During the break-in period, a careful and regular check of the oil level should be made. Maintai
l level at the full line.
oi
3. After the break-in period, thoroughly drain existing oil from crankcase.
4. Add a full charge of CHAMPLUB ISO 100 lubricant.
CHANGING TO SYNTHETIC DIESTER BASED LUBRICANT
If changing to synthetic lubricant, the following steps must be completed.
1. Compressor must run for the break-in period using CHAMPLUB ISO 100 lubricant.
2. During the break-in period, a careful and regular check of the oil level should be made. Maintai
l level at the full line.
oi
3. After the break-in period, thoroughly drain existing oil from crankcase.
4. Add a full charge of CHAMPLUB SYNTHETIC lubricant.
5. Run compressor for 200 hours.
6. Stop compressor and thoroughly drain the synthetic lubricant.
7. Add a full charge of CHAMPLUB SYNTHETIC lubricant.
8. Compressor is now ready to run for extended period before next lubricant change. Maintain oil
level at the full line.
n
n
-Series Electric 19 CQF3473 v.01
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Operation & Service April 17, 2018
Guide to Maintenance
To obtain reliable and satisfactory service, this unit requires a consistent preventive maintenance
schedule. Maintenance schedule pages are included in the back of this manual to aid in keeping the
proper records.
Before performing any maintenance function, switch main disconnect switch to "off" position to
assure no power is entering unit. "Lock Out" or "Tag Out" all sources of power. Be sure all air
pressure in unit is relieved. Failure to do this may result in injury or equipment damage.
Do not exceed 15 PSIG nozzle pressure when cleaning element parts with compressed air. Do not
direct compressed air against human skin. Serious injury could result. Never wash elements in fuel
oil, gasoline or flammable solvent.
Never operate unit without belt guard in place. Removal will expose rotating parts which can cause
injury or equipment damage.
Valves must be reinstalled in original position. Valve gaskets should be replaced each time valves
are serviced.
PRESSURE RELIEF VALVE: The pressure relief valve is an automatic pop valve. Each valve is properly
adjusted for the maximum pressure permitted by tank specifications and working pressure of the
unit on which it is installed. If it should pop, it will be necessary to drain all the air out of the tank in
order to reseat properly. Do not adjust.
TANK DRAIN VALVE: Drain valve is located at bottom of tank. Open drain valve daily to drain
condensation. Do not open drain valve if tank pressure exceeds 25 PSIG. The electric tank drainequipped compressor requires draining manually once a week.
PRESSURE SWITCH: The pressure switch is automatic and will start compressor at low pressure and
stop when the maximum pressure is reached. It is adjusted to start and stop compressor at the
proper pressure for the unit on which it is installed. Only a certified field service technician should
make adjustments to the pressure switch.
R-Series Electric 20 CQF3473 v.01
Operation & Service April 17, 2018
Guide to Maintenance (continued)
1 3 2
4
ACTUATING TUBE
MOUNTING
SENSING TUBE
ILOT VALVE: The pilot valve actuates the head unloader mechanism to provide a means of stopping or
P
starting the compression of air by the compressor without stopping or starting the engine.
The pilot valve is pre-set from the factory, according to the order specification. Only a certified field
service technician should make adjustments to the pilot valve.
ILOT VALVE PRESSURE ADJUSTMENT
P
Proceed with the following instructions while compressor is running:
1. Loosen locknut (4) and back off several turns. Do not turn differential pressure adjustment nut
(3).
2. Check reading on the tank pressure gauge. Set the compressor maximum pressure by turning
threaded cap (1) clockwise to increase pressure or counter clockwise to decrease pressure.
3. After pressure is set, tighten locknut (4). Be careful not to move threaded cap (1).
PILOT VALVE DIFFERENTIAL PRESSURE ADJUSTMENT
Proceed with the following instructions while compressor is running:
1. Loosen locknut (2) and back off several turns.
2. Check reading on the tank pressure gauge. Set the pressure to 30 psig differential (unload at
170 psig, reload at 140 psig). Turn nut (3) clockwise to increase differential pressure
c
ounterclockwise to decrease differential pressure.
or
3. After pressure is set, tighten locknut (2). Be careful not to move nut (3).
THREAD
TO HEAD UNLOADERS
FROM AIR RECEIVER
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Operation & Service April 17, 2018
Guide to Maintenance (continued)
COMPRESSOR VALVES: If compressor fails to pump air or seems slow in filling up tank, disconnect unit
from power source and remove valves and clean thoroughly, using compressed air and a soft wire
brush. After cleaning, exceptional care must be taken that all parts are replaced in exactly the same
position. All joints must be tight or the compressor will not function properly. When all valves are
replaced and connections are tight, close ball valve at tank outlet for final test. Valve gaskets should
be replaced each time valves are removed from pump.
CENTRIFUGAL UNLOADER AND UNLOADER PRESSURE RELEASE VALVE: The centrifugal unloader is
operated by two governor weights. It is totally enclosed and lubricated from the crankcase of the
compressor. When compressor starts, the governor weights automatically open, compressing the
main spring, allowing the unloader pressure release valve to close. When the compressor stops, the
main spring returns the governor weights to normal position, opening the unloader pressure release
valve and unloading the compressor. This prevents overloading the motor when starting. If air
continues to escape through the governor or unloader pressure release valve while operating, this is
an indication that the unloader pressure release valve is not closing tightly and may be held open by
a foreign substance which has lodged against the seat. In order to correct this, remove the governor
release valve cap, allowing access to unloader pressure release valve spring and ball. Clean
thoroughly and return parts in the same order in which they were removed. See Centrifugal
Unloader section in parts list for diagram. Loose drive belts can also cause unloader to leak by
preventing the compressor from reaching proper speed. (See “BELTS” page 24).
CHECK VALVE: The check valve closes when the compressor stops operating, preventing air from
flowing out of the tank through the pressure release valve. After the compressor stops operating, if
air continues to escape through the release valve, it is an indication that the check valve is leaking.
This can be corrected by removing check valve and cleaning disc and seat. If check valve is worn
badly, replace it.
Before removing check valve, be sure all air is drained out of tank and power is disconnected.
Failure to do so may result in injury or equipment damage.
HE INTERSTAGE PRESSURE RELIEF VALVE is provided to protect against interstage over pressure and is
T
factory set for maximum pressure of 75 PSIG. DO NOT RESET. If the pressure relief valve pops, it
indicates trouble. Shut down the unit immediately and determine and correct the malfunction.
Inspect the head valves. Serious damage can result if not corrected and can lead to complete
destruction of the unit. Tampering with the interstage pressure relief valve or plugging the opening
destroys the protection provided and voids all warranty.
COMPRESSOR LUBRICATION: Fill crankcase to proper level as indicated by oil sight gauge. Keep
crankcase filled as required by usage. It is recommended that only Champlub recip lubricant be
used. This is an ISO 100, non-detergent industrial oil with rust and oxidation inhibitors specially
formulated for reciprocating compressors. Do not mix oil types, weights, or brands.
-Series Electric 22 CQF3473 v.01
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Operation & Service April 17, 2018
Guide to Maintenance (continued)
OR LUBRICATION: Long life satisfactory operation of an electric motor depends in large measure
MOT
on proper lubrication of the bearings. Bearing grease will lose its lubricating ability overtime, not
suddenly. Refer to the motor manufacturer’s instructions for the type of grease and lubrication
intervals.
TORQUE VALUES:
omponent Fastener Size & Thread Model Torque
C
Governor Housing 3/8-16 R10, R15 400 Inch-lb.
Governor Housing 7/16-20 R30, R40, R70 550 Inch-lb.
Cylinder Flange 7/16-20 R10, R15, R30 400 Inch-lb.
Cylinder Flange 1/2-13 R40, R70 900 Inch-lb.
Governor Spindle Screw 7/16-20 R10, R15, R30, R40, R70 470 Inch-lb.
Rod Bolt 5/16-18 R10, R15, R30 230 Inch-lb.
Rod Bolt 7/16-20 R40, R70 400 Inch-lb.
Manifold Cap Screw 3/8-16 R10, R15, R30 200 Inch-lb.
Manifold Cap Screw 7/16-14 R40, R70 230 Inch-lb.
Flywheel Pinch Bolt 1/2-13 R10, R15, R30 600 Inch-lb.
Flywheel Cap Screw 7/16-20 R40, R70 600 Inch-lb.
-Series Electric 23 CQF3473 v.01
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Operation & Service April 17, 2018
Guide to Maintenance (continued)
TEN011448
-00
SETTING BELT TENSION
1. Proper setting of the belt tension requires a belt tension checker (part number
TEN011452).
2. Measure the belt span.
3. On the belt tension checker, position the o-ring on the span scale at the measured
belt span.
4. Position the o-ring on the deflection force scale to zero.
5. Place a straight edge across the outside diameters of the motor pulley and
compressor flywheel.
6. Place the tension checker squarely on one belt at the center of the belt span. Apply
a force on the plunger, perpendicular to the belt span until the bottom of the large
o-ring is even with the bottom of the straight edge.
7. Remove the tension checker and read the force applied from the bottom of the
small o-ring on the deflection force scale.
8. Compare the force you have applied with the values given in the table on page 25.
The force should be between the minimum (used belt) and maximum (new belt)
shown.
9. Make adjustments to the location of the motor to achieve proper tension.
(Ref. Drawing)
R-Series Electric 24 CQF3473 v.01
Operation & Service April 17, 2018
Guide to Maintenance (continued)
MODEL
H.P. PSI RPM MOTOR
BELT
BELT
QTY
USED BELT
NEW BELT
BELT DEFLECTION FORCE
PULLEY
O.D.
R10 2 125 503 5.15 A 62 1 3.4 4.9
R10 2 175 411 4.35 AX 61 1 4.1 6.0
R10 3 125 800 7.75 A 64 1 3.2 4.6
R10 3 175 754 7.35 A 64 1 3.4 4.9
R15 5 125 780 7.35 B 65 1 5.3 7.7
R15 5 175 736 6.95 B 65 1 5.6 8.1
R15 7.5 125/175 959 8.95 B 67 1 6.3 9.2
R30 7.5 125 646 7.00 B 80 2 4.3 6.2
R30 7.5 175 568 6.20 B 79 2 4.8 6.9
R30 10 125 777 8.35 B 81 2 4.8 6.9
R30 10 175 758 8.15 B 81 2 4.8 7.0
R30 15 125/175 1049 11.15 B 85 2 5.4 7.8
R40 15 125 919 11.40 B 103 2 5.3 7.7
R40 15 175 782 9.75 B 100 2 5.9 8.5
R70 20 125 715 8.95 B 100 3 5.7 8.2
R70 20 175 665 8.35 B 100 3 6.0 8.7
R70 25 125 919 11.40 B 103 3 5.7 8.3
R70 25 175 782 9.75 B 101 3 6.4 9.3
R70 30 125/175 919 11.40 B 103 3 6.6 9.6
SECTION
NUMBER
OF
BELTS
DEFLECTION
FORCE
(lbs. min)
DEFLECTION
FORCE
(lbs. max)
1. The values given in the “BELT DEFLECTION FORCE” table are calculated for nominal
conditions and are provided for reference only. The required tension may vary due to
application, manufacturing variances, component wear, etc. Drive belts must be kept tight
enough to prevent slipping. If belts slip or squeak, they need to be tightened.
2. Belt cross-section can be found printed on the outside surface of the belt.
If belts are too tight, overload will be put on motor and motor bearings.
R-Series Electric 25 CQF3473 v.01
Operation & Service April 17, 2018
Maintenance Checklist
Check oil level of
both compressor and engine if
equipped. Add quality lubricating oil as
Drain moisture from tank by opening tank drain valve located in bottom of tank.
Do not open
Clean dust and foreign matter from cylinder head, motor, fan blade
s
, air
lines, intercooler
, and
If necessary, l
oosen mounting hardware which secures motor to base. Slide motor within slots
Check the alignment of pulleys.
The compressor flywheel and
motor
sheave
should b
e aligned
Change crankcase oil.
Use type and grade oil as specified in the section on "Compressor Oil
Check entire system for air leakage around fittings, connections, and gaskets, using soap
Check and clean compressor valves
. R
eplace
valves
when worn or damaged.
Replace valve
DAILY MAINTENANCE
1
required. See Section on "Oil Specifications".
2
drain valve if tank pressure exceeds 25 PSIG.
3 Turn off compressor at the end of each day's operation. Turn off power supply at wall switch.
WEEKLY MAINTENANCE
1
tank.
2 Remove and clean intake air filters.
3 Check V-belts for proper alignment and tightness:
a Remove bolts and guard to access compressor drive.
b See “Setting Belt Tension” Section for details on how to check and set proper tension.
c
of baseplate to achieve proper tension.
d
within ±1/2° with notched belts and ±2° with wrapped belts. Adjust if necessary.
e Tighten mounting hardware to secure motor on base.
f Re-install guard and secure with bolts.
EVERY 90 DAYS OR 500 HOURS MAINTENANCE
1
Specifications".
2
solution and brush.
3 Tighten nuts and capscrews as required. See “Torque Values” section.
4
gaskets after each inspection.
5 Pull ring on all pressure relief valves to assure free movement.
-Series Electric 26 CQF3473 v.01
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Operation & Service April 17, 2018
Troubleshooting Chart
Symptom
Possible Cause(s)
Corrective Action
Motor will not start.
1.Main switch and fuses open.
1.
Check all fuses and switches. Check for
Starter trips repeatedly.
1.Improperly adjusted pressure switch.
1.
Adjust or replace.
Tank pressure builds up
slowly.
1.Air leaks.
6.
Tighten fittings.
Tank pressure builds up quickly.
1.Excessive water in tank.
1.Drain tank.
Discharge pressure relief valve
1.
Wrong pressure switch setting.
1.
Adjust to correct setting.
before servicing.
Compressor will not unload
1.
Wrong pilot valve setting.
1.
Adjust to correct setting
.
Excessive belt wear.
1.Pulley out of alignment.
1.
Realign motor pulley.
Compressor runs hot.
1.Improper flywheel rotation
1.
Check for correct rotation.
Always disconnect unit from power supply and relieve all pressure from air tank before performing any
maintenance. Failure to do so may result in personal injury or death. “Lock Out" or "Tag Out" all power
sources.
Never operate unit without belt guard in place.
Never use gasoline or flammable solvent on or around compressor unit. Explosion may result.
loose or faulty wires.
2
. Starter magnetic coils open.
3. Thermal overload tripped.
4. Defective pressure switch-contacts
will not close
5. Low voltage.
2. Check overload relay in starter. Reset
starter.
3. Reset starter. If starter trips
repeatedly, have electrical system
inspected by an electrician.
4. Repair or replace pressure switch.
Warning – Relieve tank pressure
before servicing.
5. Check with voltmeter. Be sure voltage
cor
responds to unit specifications.
pops off while compressor is
running.
(Units with head unloaders)
2
. Faulty check valve.
3. Incorrect fuse size or magnetic
starter coil.
4. Low voltage.
5. Defective motor.
2. Dirty air filter.
3. Defective compressor valves
2. Defective ASME relief valve.
2. Defective pilot valve.
3. Lack of air to pilot valve.
2. Belts too tight or too loose.
2
. Defective compressor valves.
3. Dirty air filter.
4. Dirty cylinder and/or intercooler.
Warning – Relieve tank pressure
before servicing.
2. Clean or replace
Warning – Relieve tank pressure
before servicing.
3. Be sure that fuses and coils ar
operly rated.
pr
4. Check with voltmeter. Be sure voltage
cor
responds to unit specifications.
5. Replace motor.
7. Clean or replace.
8. Install new valves.
2. Replace valve.
Warning – Relieve tank pressure
2. Replace pilot valve.
3. Open ball valve to pilot valve.
2. Adjust belt tension.
(Counter clockwise when viewed from
drive side.)
2. Install new valve plate assembly.
3. Clean or replace.
4. Clean cylinder fins and/or intercooler.
e
-Series Electric 27 CQF3473 v.01
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Operation & Service April 17, 2018
Troubleshooting Chart (continued)
Symptom
Possible Cause(s)
Corrective Action
Interstage pressure
relief valve
1.
Defective compressor valves.
1.
Install new valves.
Excessive oil consumption.
1.Dirty air filter.
1.
Clean or
replace.
Air escapes from centrifugal
1.
Cent
rifugal unloader release valve
1.
Clean or replace valve
Air
escapes from centrifugal
1.
Check valve stuck in open position.
1.Replace check valve.
System does not alternate
1.
Starter tripped.
1.
Reset starter. If starter trips repeatedly,
pops off.
unloader when unit is running
unloader when unit is stopped.
(Duplex units only)
2. Improper valve installation.
2. Wrong oil viscosity.
3. Oil leaks.
4. Worn piston rings.
5. Scored cylinder
dirty or detective.
2
. Loose wiring in alternator.
3. Defective alternator.
4. Defective motor.
2. Verify proper valve placement.
2. Refill with proper viscosity oil.
3. Tighten bolts. Replace gaskets.
4. Replace rings.
5. Replace cylinder.
Warning – Relieve tank pressure
before servicing.
have electrical system inspected by an
electrician.
2. Check and tighten all wiring
connections.
3. Replace alternator.
4. Replace motor.
-Series Electric 28 CQF3473 v.01
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Operation & Service April 17, 2018
Maintenance Log
WEEKLY
MONTHLY
EVERY 3 MONTHS
DAILY
● CHECK OIL LEVEL
● DRAIN MOISTURE FROM TANK
● CLEAN FILTER
● CLEAN COMPRESSOR
● INSPECT AIR SYSTEM
● CHANGE OIL
● INSPECT VALVE ASSEMBLIES
● TIGHTEN ALL FASTENERS
● TEST PRESSURE RELIEF VALVE
-Series Electric 29 CQF3473 v.01
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Operation & Service April 17, 2018
Maintenance Log
WEEKLY
MONTHLY
EVERY 3 MONTHS
DAILY
● CHECK OIL LEVEL
● DRAIN MOISTURE FROM TANK
● CLEAN FILTER
● CLEAN COMPRESSOR
● INSPECT AIR SYSTEM
● CHANGE OIL
● INSPECT VALVE ASSEMBLIES
● TIGHTEN ALL FASTENERS
● TEST PRESSURE RELIEF VALVE
R-Series Electric 30 CQF3473 v.01
Operation & Service April 17, 2018
Maintenance Log
WEEKLY
MONTHLY
EVERY 3 MONTHS
DAILY
● CHECK OIL LEVEL
● DRAIN MOISTURE FROM TANK
● CLEAN FILTER
● CLEAN COMPRESSOR
● INSPECT AIR SYSTEM
● CHANGE OIL
● INSPECT VALVE ASSEMBLIES
● TIGHTEN ALL FASTENERS
● TEST PRESSURE RELIEF VALVE
-Series Electric 31 CQF3473 v.01
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Operation & Service April 17, 2018
*CQF3473VER01*
*CQF3473VER01*
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