Champion R15B Operation & Maintenance Manual
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Champion R15B Operation & Maintenance Manual

Two stage/two cylinder air compressors & units
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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

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  • Page 1 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...

  • Page 2: Table Of Contents

    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................

  • Page 3: Safety And Operation Precautions

    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.

  • Page 4: Explanation Of Safety Instructions Symbols And Decals

    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.

  • Page 5: Introduction

    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.
  • Page 6 TWO STAGE AIR COMPRESSORS - MODELS R-10D & R-15B DIMENSIONS ITEM R-10 & R-15 Base-Width Bolt Down-Width 4-3/8 Bolt Down to Edge Base to Crank Ctr 5½ Overall Width Overall Height 23-1/4 Bolt Down Hole Dia. 15/32 Base-Depth 7½ Bolt Down Depth 5-3/4 Bolt Down to Edge Bolt Hole to Wheel (Max.)
  • Page 7 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 200/208V 230V 460V 575V 115V 208V 230V 1-1/2 10 (8) 12 (8) 14 (12) 8 (6) 8 (6) 7-1/2...

  • Page 8: Installation

    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.

  • Page 9: Preparation For Initial Start-Up And Operation

    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"...

  • Page 10: Maintenance

    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.
  • Page 11 EVERY 90 DAYS OR 500 HOURS MAINTENANCE Change crankcase oil. Use type and grade oil as specified in the section on "Compressor Oil Specifications". Check entire system for air leakage around fittings, connections, and gaskets, using soap solution and brush. Tighten nuts and capscrews as required.
  • Page 12 GENERAL MAINTENANCE NOTES (CONT'D) 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.

  • Page 13: Compressor Oil Specifications

    COMPRESSOR OIL SPECIFICATIONS AIR COMPRESSOR Compressors shipped on units are factory filled with ISO 100 reciprocating compressor oil. Compressors shipped as basic (pump only) do not have any oil in the crankcase. Be sure to add oil to these pumps prior to start-up.
  • Page 14 TROUBLE SHOOTING CHART FOR COMPRESSOR Always disconnect unit from power supply and relieve all pressure from air tank before performing any maintenance. Failure to do so may result in equipment damage or injury. ALock Out" or "Tag Out" all power sources. WARNING Never operate unit without belt guard in place.

  • Page 15: Trouble Shooting Guide

    EXPLANATION OF TROUBLE SHOOTING GUIDE 1/2. Check all fuses and switches on lines to motor to be sure it is receiving power. Check for loose or faulty wires. A magnetic starter embodies a reset button which may be used to place the motor back in service after some unusual power conditions.

  • Page 16: Parts List

    EXPLANATION OF TROUBLE SHOOTING GUIDE (CONT'D.) 17/18. Before servicing check valve, be sure pressure in tank is ZERO. Replace check valve. Badly worn compressors which are pumping oil may deposit carbon within after-cooler tube and check valve, restricting flow of air and possibly plugging these parts completely. These parts should be cleaned or replaced.
  • Page 17 PARTS LIST CONT'D HORIZONTAL TANK MODEL ILLUSTRATED (See Preceding Page) Motor Pulley (Not Shown) Model Elec. Hand Number Pump Motor Air Tank Valve 1 Phase 3 Phase V-Belts HR1-3 R-10D 12 HP P04390D M3590 P09315B P09315B 4L-650 HR1-6 R-10D 12 HP P01136D M3590 P09315B...
  • Page 18 R-10D AND R-15B FLYWHEEL, CYLINDER, CRANKCASE & UNLOADER ASSEMBLY ITEM PART NO. NAME REQ. ITEM PART NO. NAME REQ. Gov. Housing P12237D Cylinder NR80A M2345 Screw, Hex Head Cap M2343 Screw, Hex Head Cap NR29A Gasket, Cylinder SE1489 Gasket, Gov Housing Cover NR7A Flange NR104...
  • Page 19 R-10D AND R-15B CRANKSHAFT, PISTONS, CONNECTING ROD ASS'YS. ITEM PART NAME ITEM PART NAME R105 Crankshaft (R-10D only) R1037 Bearing, Piston Pin R155 Crankshaft (R-15B only) ZR154 Piston, Low Pressure w/Pin ZNR16 ASSY; Main Bearing ZP2709C Piston, High Pressure w/Pin OSN4 Oil Seal R1021...
  • Page 20 R-10D AND R15B VALVES & FILTER, MANIFOLD ASS'YS. ITEM PART NO. NAME REQ. ITEM PART NO. NAME REQ. P04544A Screw, Hex Head Machine M2100 Cage, Exhaust Valve RE1471A Seat, Intake Valve RE760 Spring, Valve RE1470 Disc, Valve RE1062 Disc, Valve...
  • Page 21 R10D AND R-15B INTERCOOLER & TUBING ITEM PART NO. NAME REQ. M2863 Compression Fitting ZSB250A Tube, Unloading w/Fittings M2864 Compression Fitting ZUB375 Breather Tube w/Fittings M2864 Compression Fitting M2868 Compression Fitting Z9140 Intercooler w/Fittings...

  • Page 22: Constant Speed Head Unloader Kit

    CONSTANT SPEED HEAD UNLOADER KIT Z9144 For Air Compressor Pump Models R-10D and R-15B NOTE: This is optional equipment and may not be included on your unit. The purpose of constant speed unloading is to provide a means of stopping or starting the compression of air by the compressor without stopping or starting the electric motor or gasoline engine after each cycle.

  • Page 23: Operation And Adjustment Of Pilot Valves

    OPERATION AND ADJUSTMENT OF PILOT VALVES B980-B (Ref. Drawing) PILOT VALVES ASSEMBLY PRESSURE RANGE, PART NO. PSIG M2855 75 - 95 M2854 90-120 M2853 140 - 170 The Pilot Valve is designed to act as an automatic "on" and "off" air switch. When in the "on" position it allows air to flow from the tank through the valve to some device such as a compressor suction unloader, thus actuating it.
  • Page 24 UNIT HAZARD DECAL LISTING ITEM DESCRIPTION PART NO. Retain Labels P09879A DANGER - Breathing Air P09376B DANGER - Drain Tank Daily P09430B DANGER - Valve Maintenance P09750B DANGER - High Voltage P04934A DANGER - Auto Start P09384B WARNING - Pressure/Safety Valve P09752B WARNING - Rotating Parts P09373B...
  • Page 25 UNIT HAZARD DECALS & TAGS...
  • Page 26 140-175 PSIG...

  • Page 27: Pump Hazard Decals & Tags

    PUMP HAZARD DECALS & TAGS...

  • Page 28: Record Of Maintenance Service

    RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY MONTHLY EVERY 3 MONTHS ● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL ● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES ● CHECK V-BELTS ● TIGHTEN ALL FASTENERS ●...
  • Page 29 RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY MONTHLY EVERY 3 MONTHS ● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL ● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES ● CHECK V-BELTS ● TIGHTEN ALL FASTENERS ●...
  • Page 30 RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY MONTHLY EVERY 3 MONTHS ● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL ● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES ● CHECK V-BELTS ● TIGHTEN ALL FASTENERS ●...
  • Page 32 Fax (815) 872-0421 E-mail: champion@championpneumatic.com Copyright 8 2000 Gardner Denver, Inc. Plants in Princeton, IL, and Manteca, CA Printed in U.S.A. Due to Champion = s continuing product development program, specifications and materials are subject to change without notice or obligation...

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