Champion R15B, HR3-6 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.
R15B HR3-6
Form No. F3231 REV 12/00
TABLE OF CONTENTS
_______________________________________________________
Subject
Page
Safety And Operation Precautions ......................................................... 3
Explanation Of Safety Instructions Symbols And Decals....................... 4
Introduction .............................................................................................5
Warranty.................................................................................................. 5
Dimensions And Specifications ........................................................6 & 7
Installation ............................................................................................... 8
Preparation For Initial Start-Up And Operation....................................... 9
Maintenance............................................................................ 10,11 & 12
Compressor Oil Specifications.............................................................. 13
Trouble Shooting Guide.......................................................... 14,15 & 16
Parts List ............................................................. 16, 17, 18, 19 , 20 & 21
Constant Speed Head Unloader Kit .....................................................22
Operation And Adjustment Of Pilot Valves........................................... 23
Unit Hazard Decal & Tags ................................................... 24 , 25 & 26
Pump Hazard Decals & Tags ............................................................... 27
Record Of Maintenance Service............................................ 28, 29 & 30
2
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.
3
EXPLANATION OF SAFETY INSTRUCTIONS SYMBOLS AND DECALS
DANGER
Indicates immediate hazards which will result in severe injury or death.
WARNING
Indicates hazards or unsafe practice which could result in severe injury or death.
CAUTION
Indicates hazards or unsafe practice which could result in damage to the Champion compressor
or minor injury.
OBSERVE, UNDERSTAND, AND RETAIN THE INFORMATION GIVEN IN THE SAFETY PRECAUTION DECALS
AS SHOWN IN THE PARTS LIST SECTION.
DANGER
This Oil-Less compressor must not be used for breathing air, unless proper downstream filtraton
and purification is added. To use for breathing air without proper downstream equipment will
cause serious injury whether air is supplied direct from the compressor source or to the breathing
tanks for later use. Any and all libilities 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, without proper downstream filtration and purificaton, 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.
4
INTRODUCTION
____________________________________________________________________
Your new Champion Reciprocating Air Compressor is constructed to exacting standards of material and
workmanship.
The instructions in this manual have been prepared to ensure that the Champion air compressor will give
long and satisfactory service.
A copy of this manual must be given to the personnel responsible for installing and operating the Champion
air compressor or unit.
Although precautions have been taken to prevent damage to your compressor or unit by freight carrier, the
unit must be carefully examined and the carrier notified within 24 hours in the event of mishandling.
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, excluding head valves. Valves, controls and accessories
are 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.
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.
5
TWO STAGE AIR COMPRESSORS - MODELS R-10D & R-15B
PERFORMANCE
DIMENSIONS
ITEM R-10 & R-15
Base-Width
A
Bolt Down-Width
B
Bolt Down to Edge
C
Base to Crank Ctr
D
Overall Width
E
Overall Height
F
Bolt Down Hole Dia.
I
Base-Depth
J
Bolt Down Depth
K
Bolt Down to Edge
L
Bolt Hole to Wheel (Max.)
M
Flywheel Width
N
Crank Diameter
O
Flywheel Diameter
P
Flywheel Grooves
Q
Overall Depth
R
NOTE: H.P. Exhaust Opening 3/4" Tubing.
10
4-3/8
5/8
5½
18
23-1/4
15/32
7½
5-3/4
7/8
3-5/8
2½
1-5/16
16½
2VB
20
PUMP
OUTPUT
PRESS.
PSIG
MOTOR
H.P.
DISPL.
CFM
COOLING
AIR FLOW
CFM
HEAT
REJECTION
BTU/HR
PUMP
RPM
APPROX.
PULLEY O.D.
INCHES
R-10D 125 1-1/2 11.0 660 3360 570 5.55
R-10D 175 1-1/2 10.5 625 3360 542 5.25
R-10D 125 2 14.8 875 4480 760 7.35
R-10D 175 2 14.1 835 4480 725 7.0
R-15B 125 3 14.5 565 6700 490 4.75
R-15B 175 3 12.8 505 6700 440 4.31
R-15B 125 5 21.9 868 12,000 750 7.35
R-15B 175 5 20.7 820 12,000 710 7.00
R-15B 175 7-1/2 30.2 1195 16,800 1035 9.75
All data is based on 1725 RPM electric motors as a power source.
Flywheel Rotation; Clockwise When Min. RPM 400
Viewed From Front - Flywheel to Rear Max. RPM 1050
SPECIFICATIONS
BORE & STROKE
MODEL
R-10D 4-5/8 & 2-1/2 x 2 2 2 QT. 107 175 PSIG .01942*
R-15B 4-5/8 & 2-1/2 x 3 2 2 QT. 109 175 PSIG .02914
INCHES
* Clearance Volume Modified to Effective .014 Cu. Ft./Rev.
NO. CYLS.
OIL CAPY.
6
WT. (LBS)
MAX.
PRESS.
CU FT./REV.
ELECTRIC WIRING (BASED ON 1999 NEC)
Wire Size (Rubber Covered) AWG NO.
Copper Conductor -- 75°C Temp Rating -- 30°C Ambient
MOTOR
3 PHASE 1 PHASE
HP
200/208V 230V 460V 575V 115V 208V 230V
1-1/2 14 14 14 14 10 14 14
2 14 14 14 14 8 12 12
3 14 14 14 14 8 10 10
5 10 (8) 12 (8) 14 (12) 14 - 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.
PIPE SIZES FOR COMPRESSED AIR LINES - R-10D & R-15B
(Based on Clean, Smooth Schedule 40 Pipe)
LENGTH OF PIPE LINES IN FEET
25 50 75 100 150 200 250 300
R-10D
3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
R-15B
Values in ( ) for Duplex Unit.
Never use plastic pipe or improperly rated metal pipe. Improper piping materials can burst and
cause injury or property damage.
3/4 (1) 3/4 (1) 3/4(1) 3/4 (1) 1 (1-1/4) 1 (1-1/4) 1 (1-1/4) 1 (1-1/4)
7
INSTALLATION
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 installa-tions 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.
DANGER
Do not install isolating valves betweencompressor 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.
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.
All wiring should be performed by a licensed electrician or electrical contractor. Wiring must meet applicable codes
for area of installation.
Recommended electrical wiring specifi-cations are listed in "Specifications" section.
If ordered with a mounted starter, compressor unit is pre-wired at factory. It is necessary only to bring lines
fromproperly sized disconnect switch to magnetic starter mounted on compressor, and attach to terminals as
indicated on schematic diagram located inside cover of control. Be sure that power circuit and voltage correspond
with the specifications
.
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.
8
INSTALLATION (CONT’D)
GROUNDING INSTRUCTIONS
This product should be connected to a grounded, metallic, permanent wiring system, or an equipment-
grounded 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. See
recommended piping sizes listed in "Specifications" section. 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.
PREPARATION FOR INITIAL START-UP AND OPERATION
1. Pull main disconnect switch to unit and tag out to assure that no power is coming into the unit. Connect
power leads to starter.
WARNING
Do not attempt to operate compressor on voltage other than that specified on order or on compressor
motor.
2. Check compressor oil level. Add oil as required. See section on "Oil Specifications".
3. Inspect unit for any visible signs of damage that would have occurred in shipment or during installation.
4. Activate main disconnect switch.
5. "Jog" motor and check for proper rotation by direction of arrow. If rotation is wrong, reverse input
connections on the magnetic starter.
6. Close receiver outlet hand valve and start unit.
7. With receiver hand valve closed, let machine pump up to operating pressure. At this stage the automatic
controls will take over. Check for proper cycling operation.
8. Check for proper operation of any options, e.g. LOSC or head unloaders with pilot valve. Refer to individual
option instruction sheet.
9. When the initial run period has shown no operating problems, shut unit down and recheck oil level.
10. Open receiver hand valve. The air compressor unit is now ready for use.
9
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.
WARNING
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.
DAILY MAINTENANCE
1. Check oil level of both compressor and engine if so equipped. Add quality lubricating oil as required. See
Section on "Oil Specifications".
2. Drain moisture from tank by opening tank drain valve located in bottom of tank. Do not open 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. Clean dust and foreign matter from cylinder head, motor, fan blade, air lines, intercooler and tank.
2. Remove and clean intake air filters.
WARNING
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.
3. Check V-belts for tightness. The V-belts must be tight enough to transmit the necessary power to the
compressor. Adjust the V-belts as follows:
Remove bolts and guard to access compressor drive.
Loosen mounting hardware which secures motor to base. Slide motor within slots of baseplate to desired
position.
Apply pressure with finger to one belt at midpoint span. Tension is correct if top of belt aligns with bottom
of adjacent belt. Make further adjustments if necessary.
Check the alignment of pulleys. Adjust if necessary.
Tighten mounting hardware to secure motor on base.
Re-install guard and secure with bolts.
WARNING
Never operate unit without belt guard in place. Removal will expose rotating parts which can cause
injury or equipment damage.
10
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