Champion R Series, R30D, R15B Operation & Service Manual
R-SERIES
THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD ALWAYS
Air Compressors and Units
OPERATION & SERVICE MANUAL
Engine 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.
CQF3474 v.00 Jan.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 ........................................................................................................... 5
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 ......................................................................................................................... 15
Operation .............................................................................................................................................. 16
Compressor Oil Specifications................................................................................................................ 18
Guide to Maintenance ........................................................................................................................... 20
Maintenance Checklist .......................................................................................................................... 26
Troubleshooting Chart ........................................................................................................................... 27
Maintenance Log ................................................................................................................................... 28
Notes .................................................................................................................................................... 31
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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.
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 OR DIESEL 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.
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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 safety codes, as well as the Occupational Safety and Health Act (OSHA).
3. Do not attempt to remove any compressor parts without first relieving the entire system of pressure.
4. Do not attempt to service any part while machine is in an operational mode.
5. Do not operate the compressor at pressures in excess of its rating.
6. Do not operate compressor at speeds in excess of its rating.
7. Periodically check all safety devices for proper operation. Do not change pressure setting or restrict operation
i
n any way.
8. Be sure no tools, rags or loose parts are left on the compressor or drive parts.
9. Do not use flammable solvents for cleaning the air inlet filter or element and other parts.
10. 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.
11. Do not operate the compressor without guards, shields and screens in place.
12. 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.
13. Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic fumes.
14. Be careful when touching the exterior of a recently run engine - it may be hot enough to be painful or cause
injury.
15. Inspect unit daily to observe and correct any unsafe operating conditions found.
16. Do not "play around" with compressed air or direct air stream at body. This can cause injuries.
17. Compressed air from this machine must not be used for food processing or breathing air without adequate
downstream filters, purifiers and controls.
18. Always use an air pressure regulating device at the point of use. Do not use air pressure greater than marked
maximum pressure of attachment.
19. Check hoses for weak or worn condition before each use and make certain that all connections are secure.
20. Always wear safety glasses when using a compressed air blow gun.
21. Engine drive unit precautions:
a. Understand the operation of all controls and learn how to stop the engine quickly in case of emergency.
Make sure the operator receives adequate instruction before operating the equipment.
b. Do not allow children to operate the engine. Keep children and pets away from the area of operation.
c. Your engine’s exhaust contains poisonous carbon monoxide. Do not run the engine without adequate
ventilation. Never run the engine indoors.
d. The engine and exhaust become very hot during operation. Keep the engine at least 3 feet away from
buildings and other equipment during operation. Keep flammable materials away. Do not plac
ng on the engine while it is running.
anythi
e
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 reciprocating compressor must not be used for breathing air. To
do so will cause serious injury
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.
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.
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.
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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 WARNING
– Tank Pressure
3 DANGER
– Breathing Air
4 DANGER
– Drain Tank Daily
5 WARNING
– Pressure/Safety Valve
6 NOT USED
7 DANGER
– Valve Maintenance
8 NOT USED
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: 140
-
175 PSIG
15 NOTICE
– Read and Retain Manuals
16 NOT USED
17 DECAL
– Rotation Direction
18 NOT USED
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
Pump Hazard Decal List – See Page 9
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Unit Hazard Decals
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Pump Hazard Decals
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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.
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 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 required
to be anchored to floor or truck bed. 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 floor without vibration isolator pads will not be
warranted against cracking. Champion vibration isolator pads must be used for extended warranty
to apply to ASME air receivers. See “Air Receiver Installation” section.
the tank foot. This can cause abnormal vibration and possible cracking of the air receiver, resulting
in injury or equipment damage.
4. If installing base mounted unit, make certain the pressure limiting controls are properly installed
and operational. The unloading system requires a control air pressure line from the air receiver to
be connected to the pilot valve fitting on the pump.
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.
6. Engine driven units installed indoors must have proper engine exhausting out of building. See Safety
& Precautions Item 21 (page 5).
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