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Champion C453-B Operation Maintenance Manual & Parts List

Two stage/two cylinder air compressors & units featuring the r10 & r15 pumps
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TWO STAGE/TWO CYLINDER AIR COMPRESSORS & UNITS
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
Form No. F3231
VER: 20
FEATURING THE R10 & R15 PUMPS
C453-B
(Ref. Drawing)
11/25/2015
OPERATION/MAINTENANCE
MANUAL & PARTS LIST
MODEL HR2-6 UNIT
C452-B
(Ref. Drawing)

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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. C453-B C452-B (Ref. Drawing) (Ref. Drawing) MODEL R15B COMPRESSOR MODEL HR2-6 UNIT Form No.
  • Page 2 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.

  • Page 3: Table Of Contents

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

  • Page 4: 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 5: 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 minor injury.

  • Page 6: Introduction

    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...
  • Page 7 TWO STAGE AIR COMPRESSORS - MODELS R10D & R15B DIMENSIONS ITEM R10D & R15B Base-Width 10” Bolt Down-Width 4-3/8” Bolt Down to Edge 5/8” Base to Crank Ctr 5-1/2” Overall Width Overall Height 23-1/4” Bolt Down Hole Dia. 15/32” Base-Depth 7-1/2”...

  • Page 8: Warranty

    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 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.
  • Page 10 INSTALLATION (CONT’D) 311CAD546-B (Ref. Drawing) 312CAD546-B (Ref. Drawing)

  • Page 11: Operation

    INSTALLATION (CONT’D) 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 equipment- grounding terminal or lead on the product.
  • Page 12 OPERATION (CONT’D) Units furnished with head unloaders are equipped with a needle valve, pilot valve and head unloaders to provide continuous run capabilities. The pilot valve acts as an automatic air switch allowing air to flow from the receiver to the head unloader mechanism, thus actuating it. To operate unit in continuous run, open needle valve located next to pilot valve.

  • Page 13: 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. Before performing any maintenance function, switch main disconnect switch to "off" position to assure no power is entering unit.
  • Page 14 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 15 GENERAL MAINTENANCE (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. When the compressor stops, the main spring returns the governor weights to normal position opening the unloader pressure release valve and unloading the compressor.
  • Page 16 COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running: Loosen locknut (4) and back off several turns. Do not turn differential pressure adjustment nut (3). Check reading on the tank pressure gauge. Set the compressor maximum pressure by turning threaded cap (1) clockwise to increase pressure or counter clockwise to decrease pressure.

  • Page 17: Compressor Oil Specifications

    “Emulsification of oil (white milky substance) indicates unsafe accumulation of moisture and may be evidence compressor is oversized for application. Failure to promptly consult your local distributor, or Champion Customer Service, can be grounds to deny warranty.” NOTES: 1. Normal break-in period of Champion air compressors is 25 hours.
  • Page 18 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 19 Troubleshooting Chart (Cont’d Symptom Possible Cause(s) Corrective Action Air escapes from centrifugal unloader Centrifugal unloader release valve Clean or replace valve when unit is running dirty or detective. Air escapes from centrifugal unloader Check valve stuck in open position. Replace check valve. when unit is stopped.
  • Page 20 PARTS ILLUSTRATION MODELS: HR2-3, HR2-6, HR2-8, HR3F-3, HR3F-6, HR3F-8, HR3F-12, HR5-3, HR5-6, HR5-8, HR5-12, HR7F-6, HR7F-8 & HR7F-12 C454-B (Ref. Drawing)
  • Page 21 REPAIR PARTS LIST MODELS HR2-3 HR2-6 HR2-8 HR3F-3 HR3F-6 HR3F-8 1. Pump R10D R10D R10D R10D R10D R10D 2. Pressure Gauge M519C M519C M519C M519C M519C M519C 3. Belt Guard (Standard) CC1066253 CC1060936 CC1060936 CC1066253 CC1060936 CC1060936 3. Belt Guard (With ACAC) CC1066254 CC1060937 CC1060937...
  • Page 22 UNIT REPAIR PARTS ILLUSTRATION MODELS: VR2-6, VR2-8, VR3F-6, VR3F-8, VR3F-12, VR5-6, VR5-8, VR5-12, VR7F-6, VR7F-8, & VR7F-12 C455-B (Ref. Drawing)
  • Page 23 REPAIR PARTS LIST MODELS VR2-6 VR2-8 VR3F-6 VR3F-8 VR3F-12 VR5-6 VR5-8 VR5-12 VR7F-6 VR7F-8 VR7F-12 1. Pump R10D R10D R10D R10D R10D R15B R15B R15B R15B R15B R15B 2. Pressure Gauge M519C M519C M519C M519C M519C M519C M519C M519C M519C M519C M519C 3.
  • Page 24 UNIT REPAIR PARTS ILLUSTRATION MODELS: HR2D-8, HR2D-12, HR3DF-8, HR3DF-12 HR5D-8, HR5D-12, HR7DF-12 & HR7DF-25 C457-B (Ref. Drawing)
  • Page 25 REPAIR PARTS LIST MODELS HR2D-8 HR2D-12 HR3DF-8 HR3DF-12 HR5D-8 HR5D-12 HR5D-25 HR7DF-12 HR7DF-25 1. Pump R10D R10D R10D R10D R15B R15B R15B R15B R15B 2. Pressure Gauge M519C M519C M519C M519C M519C M519C M519C M519C M519C 3. Belt Guard (Standard) CC1060945 CC1060936 CC1060945...

  • Page 26: Parts List

    UNIT REPAIR PARTS ILLUSTRATION MODELS: BR-2, BR-3F, BR-5 & BR-7F 307CAB797-A (Ref. Drawing) REPAIR PARTS LIST MODELS BR-2 BR-3F BR-5 BR-7F 1. Pump R10D R10D R15B R15B 2. Belt Guard (Standard) CC1060936 CC1060936 CC1060936 CC1060936 2. Belt Guard (With ACAC) CC1060937 CC1060937 CC1060937...
  • Page 27 REPAIR PARTS ILLUSTRATION AIR COOLED AFTERCOOLER 336CAS810-A (Ref. Drawing) Repair Parts List Repair Parts List Air Cooled Aftercooler Air Cooled Aftercooler Ref. No. Description Part Number Qty. Ref. No. Description Part Number Qty. Ref. No. Description Part Number Aftercooler P14477B Discharge Tube, Lower 30GH P10705B Belt Guard, Aftercooler...
  • Page 28 Compressor Repair Parts Illustration Models: R10D & R15B C389-B (Ref. Drawing) Repair Parts List Compressor Models R10D & R15B Ref. No. Description Part No. Qty. Crankcase M1820 Pipe plug 64AA5 Flywheel NR7A Hex head cap screw M738 Hex nut M2955 Pipe plug 64A5 Oil level gauge...
  • Page 29 Repair Parts List Compressor Models R10D & R15B Ref. No. Description Part No. Qty. Lock washer M3468 Hex head cap screw M2345 Flat washer M912A Governor spring SE590 Spring sleeve SE587 Governor housing cover RE10100A Unloader muffler assembly Z4593 Hex head machine screw M3473 Release valve assembly Z12414A...
  • Page 30 Repair Parts List Compressor Models R10D & R15B Ref. No. Description Part No. Qty. Gasket, Valve, LPIN, R10-30 CQP14832A Intake valve cage M2098 Valve spring RE1458 Valve disc RE1470 Intake valve seat RE1471 Hex head machine screw P04544A Low pressure intake manifold P09669C High pressure intake valve assembly Z11937...
  • Page 31 Compressor Repair Parts Illustration Models: R10D & R15B C420-B (Ref. Drawing) Ref. No. Description Part No. Qty. Compression Fitting M2879 Tube, Unloading w/Fittings ZSB250A Compression Fitting M2864 Breather Tube w/Fitting ZUB375 Compression Fitting M2864 Compression Fitting 86A40 Intercooler w/Fittings Z9140 Compression Nut VP1061773...
  • Page 32 CONSTANT SPEED HEAD UNLOADER For Air Compressor Models R10D and R15B 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 33 UNIT HAZARD DECAL LISTING PAGE DESCRIPTION PART NO. PRODUCT LIABILITY DECAL SHEET - MASTER P10157A Unit Pressure Setting NOT USED DANGER – Breathing Air DANGER – Drain Tank Daily WARNING – Pressure/Safety Valve NOT USED DANGER – Valve Maintenance DANGER – High Voltage WARNING –...
  • Page 34 UNIT HAZARD DECALS...
  • Page 35 PUMP HAZARD DECALS...
  • Page 36 *F3231VER20* *F3231VER20* For additional information, contact your local representative or visit: www.championpneumatic.com/contactus.aspx ©2015 Gardner Denver, Inc. Printed in U.S.A.

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C452-b

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