Champion R10D, R15B, HR2-6 Operation & Maintenance Manual
OPERATION/MAINTENANCE
MANUAL & PARTS LIST
TWO STAGE/TWO CYLINDER AIR COMPRESSORS & UNITS
FEATURING THE R10 & R15 PUMPS
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.
MODEL R15B COMPRESSOR MODEL HR2-6 UNIT
Form No. F3231 Ver: 02 01/08/2004
C453-A
Drawing)
(Ref.
C452-A
Drawing)
(Ref.
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.
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: (815) 875-3321
Fax: (815) 872-0421
E-Mail: Champion@Championpneumatic . 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
Safety And Operation Precautions.................................................................... 4
Explanation Of Safety Instructions Symbols And Decals.................................. 5
Introduction ....................................................................................................... 6
Warranty............................................................................................................ 6
Dimensions And Specifications......................................................................... 7
Installation....................................................................................... 8, 9, 10 & 11
Operation ................................................................................................11 & 12
Maintenance................................................................................. 13,14, 15 & 16
Compressor Oil Specifications........................................................................ 17
Lubricant ......................................................................................................... 17
Torque Valves................................................................................................. 17
Trouble Shooting Guide .......................................................................... 18 & 19
Parts List ............................................................................................. 20 thru 30
Constant Speed Head Unloader Kit................................................................ 31
Unit Hazard Decal & Tags .................................................................... 32 & 33
Pump Hazard Decals & Tags......................................................................... 34
Record Of Maintenance Service ..................................................................... 35
3
SAFETY AND OPERATION PRECAUTIONS
_______________________________________________________________________________________
Because an air compressor is a piece of machinery with moving and rotating parts, the same precautions should be
observed as with any piece of machinery of this type where carelessness in operation or maintenance is hazardous to
personnel. 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. "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 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 compressed air gun.
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.
4
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 reciprocating compressor must not be used for breathing air. 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 injury, 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 the 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.
5
INTRODUCTION
____________________________________________________________________
Champion R Series compressor 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 dayto-day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical
operation and minimum downtime.
Champion Five Year Warranty
"R" Series Compressors
CHAMPION warrants each new compressor pump manufactured by CHAMPION, mounted on a factory assembled unit, to
be free from defects in material and workmanship under normal use and service for a period of sixty (60) months from date
of installation or sixty-six (66) months from date of shipment by CHAMPION or CHAMPION distributor, whichever may
occur first. Applies to the compressor pump only
warranted for the first year only. Compressor pumps purchased separately would carry a one year warranty.
This five year extended warranty will be prorated over the 5 years as follows:
First Year - 100% Allowance, Parts and Labor
Second Year - 90% Allowance, Parts and Labor
Third Year - 80% Allowance, Parts and Labor
Fourth Year - 70% Allowance, Parts and Labor
Fifth Year - 60% Allowance, Parts and Labor
Applies to CHAMPION logo, tank or base mounted complete compressors only.
, excluding head valves. Valves, controls and accessories are
Express Limited Warranty
CHAMPION warrants each new air compressor unit 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 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, GASOLINE ENGINES 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.
The extended five year warranty will apply to ASME air receivers provided they are installed on rubber vibro isolator pads.
When a compressor pump, or component is changed or replaced during the warranty period, the new/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 OR 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
TWO STAGE AIR COMPRESSORS - MODELS R10D & R15B
DIMENSIONS
C416-A
(Ref. Drawing)
ITEM R10D & R15B
A
Base-Width
B
Bolt Down-Width
C
Bolt Down to Edge
D
Base to Crank Ctr
E
Overall Width
F
Overall Height
I
Bolt Down Hole Dia.
J
Base-Depth
K
Bolt Down Depth
L
Bolt Down to Edge
M
Bolt Hole to Wheel (Max.)
N
Flywheel Width
O
Crank Diameter
P
Flywheel Diameter
Q
Flywheel Grooves
R
Overall Depth
NOTE: H.P. Exhaust Opening 3/4" Tubing.
10”
4-3/8”
5/8”
5-1/2”
18
23-1/4”
15/32”
7-1/2”
5-3/4”
7/8”
3-5/8”
2-*1/2”
1-5/16”
16-1/2”
2VB
20”
Flywheel Rotation – Clockwise when viewed from
front, flywheel to rear.
SPECIFICATIONS
MODEL
R10D 4-5/8 & 2-1/2 x 2 2 2 107 175 .01942* 400/1050
R15B 4-5/8 & 2-1/2 x 3 2 2 109 175 .02914 400/1050
BORE & STROKE
(INCHES)
* Clearance Volume Modified to Effective .014 Cu. Ft./Rev.
NO. OF
CYLINDERS
OIL CAPACITY
(QTS.)
WEIGHT
(LBS)
PRESSURE
(PSIG)
CU FT./REV.
MIN./MAX.
PERFORMANCE
PUMP
OUTPUT
PRESS.
PSIG
MOTOR
H.P.
PUMP
RPM
DISPL.
CFM
COOLING
AIR FLOW
CFM
HEAT
REJECTI
ON
BTU/HR
APPROX.
PULLEY
O.D.
INCHES
R10D 125 1-1/2 570 11.0 660 3360 5.55
R10D 175 1-1/2 542 10.5 625 3360 5.25
R10D 125 2 760 14.8 875 4480 7.35
R10D 175 2 725 14.1 835 4480 7.00
R15B 125 3 490 14.5 565 6700 4.75
R15B 175 3 440 12.8 505 6700 4.31
R15B 125 5 750 21.9 868 12,000 7.35
R15B 175 5 710 20.7 820 12,000 7.00
R15B 175 7-1/2 1035 30.2 1195 16,800 9.75
All data is based on 1725 RPM electric motors as a power source.
Pulley Dia. (approx.) = Compressor RPM x Flywheel Dia.
Motor or Engine RPM
RPM
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 fan
bladed flywheel, which cools the compressor, is impeded. Permanently mounted units should have
flywheel 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.
Avoid putting a stress on a tank foot by pulling it down to floor. This will only result in abnormal vibration,
and possible cracking of Air Receiver. It is recommended that optional vibro-isolator pads be installed on
unit. Tanks bolted directly to a concrete floor without padding will not be warranted against cracking.
Champion vibro-isolators must be used for extended warranty to apply to ASME air receivers.
4. If installing a bare pump or a base mounted unit, make certain the system has adequate pressure limiting
controls. Controls could be a pressure switch for start/stop operation or a pilot valve for continuous
operation. If a pilot valve is used, the compressor must be equipped with head unloaders. Control air must
be piped from the air receiver to the pilot valve.
5. A properly sized air check valve must be installed in the discharge piping, between the compressor outlet
and the inlet of any receiver tank(s) in the system.
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.
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 in 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
correspond to the unit specifications. Branch circuit protection must be provided at installation a specified
in the National Electrical Code.
All wiring should be preformed by a licensed electrian 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) - 75°C COPPER - 30°C AMBIENT
MOTOR
HP
200/208V 230V 460V 575V 115V 208V 230V
3 PHASE 1 PHASE
1-1/2 14 14 14 14 10 14 14
2 14 (14) 14 (14) 14 (14) 14 (14) 8 (6) 12 (10) 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)
7-1/2 8 (6) 10 (6) 14 (10) 14 (10) -- -- 6 (4)
Values in ( ) for Duplex Unit w/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.
Figure 1 - Simplex Wiring Diagram
9
INSTALLATION (CONT’D)
B1257-A
(Ref. Drawing)
10
B1258-A
(Ref. Drawing)
INSTALLATION (CONT’D)
CAUTION
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.
GROUNDING 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
Connection 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)
MODEL 25’ 50’ 100’ 200’ 300’
R10D 3/4” 3/4” 3/4” 3/4” 3/4”
R15B 3/4” (1”) 3/4” (1”) 3/4” (1”) 1” (1-1/4”) 1” (1-1/4”)
Values in ( ) are for duplex unit.
WARNING
Never use plastic pipe or improperly rated metal pipe. Improper piping material can burst and cause injury
or property damage.
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.
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 and lag 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 pressure switch but remains above the cut-in pressure setting of the lag
pressure switch, only one compressor will run until receiver pressure reaches the cut-out pressure of the lead
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 pressure
switch, both compressors run until receiver pressure reaches the cut-out pressure setting of the lead pressure
switch.
11
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