Champion R-70, R-40, R-10, R-30, R-15 User Manual
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.
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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
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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
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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
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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
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Pump Hazard Decals
F
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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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