Champion C452-B, Operation Maintenance Manual & Parts List

Page 1: ...NTAINS 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 MODEL HR2 6 UNIT Form No F3231 VER 20 11 25 2015 C453 B Ref Drawing C452 B Ref Drawing ...

Page 2: ...h 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...

Page 3: ...ctions Symbols And Decals 5 Introduction 6 Warranty 6 Dimensions And Specifications 7 Installation 8 9 10 11 Operation 11 12 Maintenance 13 14 15 16 Compressor Oil Specifications 17 Lubricant 17 Torque Valves 17 Trouble Shooting Guide 18 19 Parts List 20 thru 31 Constant Speed Head Unloader Kit 32 Unit Hazard Decal Tags 33 34 Pump Hazard Decals Tags 35 ...

Page 4: ...eration 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 witho...

Page 5: ... must not be used for breathing air without adequate downstream 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 breat...

Page 6: ...it 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 bythird parties such as ELECTRIC MOT...

Page 7: ... STROKE INCHES NO OF CYLINDERS OIL CAPACITY QTS WEIGHT LBS PRESSURE PSIG CU FT REV MIN MAX RPM R10D 4 5 8 2 1 2 x 2 2 2 107 175 01942 400 1050 R15B 4 5 8 2 1 2 x 3 2 2 109 175 02914 400 1050 Clearance Volume Modified to Effective 014 Cu Ft Rev PERFORMANCE PUMP OUTPUT PRESS PSIG MOTOR H P PUMP RPM DISPL CFM COOLING AIR FLOW CFM HEAT REJECTIO N BTU HR APPROX PULLEY O D INCHES R10D 125 2 562 10 9 647...

Page 8: ...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...

Page 9: ...HASE 200 208V 230V 460V 575V 115V 208V 230V 1 1 2 14 14 14 14 10 14 14 2 14 14 14 14 14 14 14 14 8 6 12 10 12 10 3 14 10 14 12 14 14 14 14 8 4 10 8 10 8 5 10 8 12 8 14 12 14 12 8 6 8 6 7 1 2 8 6 10 6 14 10 14 10 6 3 6 4 Values in for Duplex Unit w one incoming power line to both motors All models require a properly sized magnetic starter as specified in the National Electric Code NEC See Figure 1 ...

Page 10: ...10 INSTALLATION CONT D 311CAD546 B Ref Drawing 312CAD546 B Ref Drawing ...

Page 11: ...or has been inspected thoroughly tested and approved at the factory For this unit to give long satisfactory service it must be installed and operated properly This compressor has been designed for a 80 ON 20 OFF duty cycle Simplex units have a pressure switch that senses changes in receiver pressure and automatically starts and stops the compressor at preset pressure limits If the receiver pressur...

Page 12: ...mage that would have occurred in shipment or during installation 2 Pull main disconnect switch to unit to assure that no power is coming into the unit Lock Out or Tag Out switch Connect power leads to start Do not attempt to operate compressor on voltage other than that specified on order or on compressor motor 3 Check compressor oil level Add oil as required See Compressor Oil Specifications Sect...

Page 13: ...ANCE 1 Clean dust and foreign matter from cylinder head motor fan blade air lines intercooler and tank 2 Remove and clean intake air filters 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...

Page 14: ...Open drain valve daily to drain condensation Do not open drain valve if tank pressure exceeds 25 PSIG The automatic tank drain equipped compressor requires draining manually once a week PRESSURE SWITCH The pressure switch is automatic and will start compressor at low pressure and stop when the maximum pressure is reached It is adjusted to start and stop compressor at the proper pressure for the un...

Page 15: ...his can be corrected by removing check valve and cleaning disc and seat If check valve is worn badly replace same Before removing check valve be sure all air is drained out of tank and power is disconnected Failure to do so may result in injury or equipment damage THE INTERSTAGE PRESSURE RELIEF VALVE is provided to protect against interstage over pressure and is factory set for maximum pressure of...

Page 16: ...be 5 psig less than setting of pressure switch 3 After pressure is set tighten locknut 4 Be careful not to move threaded cap 1 COMPRESSOR PILOT VALVE DIFFERENTIAL PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running 1 Loosen locknut 2 and back off several turns 2 Check reading on the tank pressure gauge Set the pressure to 30 psig differential unload at 170 psig ...

Page 17: ...ld be made Maintain oil level at the full line CHANGING TO SYNTHETIC LUBRICANT Applies to diester based synthetic lubricant only If changing to synthetic lubricant the following steps must be completed 1 Compressor must run for a 25 hour break in period using ChampLub ISO 100 oil 2 Thoroughly drain existing oil from crankcase 3 Fill crankcase with a full charge of synthetic lubricant 4 Run compres...

Page 18: ...y rated 4 Check with voltmeter Be sure voltage corresponds to unit specifications 5 Replace motor Tank pressure builds up slowly 1 Air leaks 2 Dirty air filter 3 Defective compressor valves 1 Tighten fittings 2 Clean or replace 3 Install new valve plate assembly Tank pressure builds up quickly 1 Excessive water in tank 1 Drain tank Discharge pressure relief valve pops off while compressor is runni...

Page 19: ...l unloader when unit is stopped 1 Check valve stuck in open position 1 Replace check valve Warning Relieve tank pressure before servicing System does not alternate Duplex units only 1 Starter tripped 2 Loose wiring in alternator 3 Defective alternator 4 Defective motor 1 Reset starter If starter trips repeatedly have electrical system inspected by an electrician 2 Check and tighten all wiring conn...

Page 20: ...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: ... 5L680 2 5L680 2 5L680 2 5L650 2 5L650 2 5L650 2 HR3F 12 HR5 3 HR5 6 HR5 8 HR5 12 HR5 25 HR7F 6 HR7F 8 HR7F 12 1 Pump R10D R15B R15B R15B R15B R15B R15B R15B R15B 2 Pressure Gauge M519C M519C M519C M519C M519C M519C M519C M519C M519C 3 Belt Guard Standard CC1060936 CC1066253 CC1060936 CC1060936 CC1060936 CC1060936 CC1060936 CC1060936 CC1060936 3 Belt Guard With ACAC CC1060937 CC1066254 CC1060937 C...

Page 22: ...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: ...re Relief Valve M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 9 Motor 2 HP 2 HP 3 HP 3 HP 3 HP 5 HP 5 HP 5 HP 7 5 HP 7 5 HP 7 5 HP 10 Tank P01161D CC1048923 P01161D CC1048923 P02212D P01161D CC1048923 P02212D P01161D CC1048923 P02212D 11 Isolation Valve M3590 M3590 M3590 M3590 CQM3756 M3590 M3590 CQM3756 M3590 M3590 CQM3756 12 Pulley 125PSIG P12213A P12213A CC1005979 CC1005979 ...

Page 24: ...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: ...5 PSIG P14202A P14202A P14202A P14202A P14202A P14202A P14202A P14202A P14202A 9 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 10 Motor 2 HP 2 HP 3 HP 3HP 5HP 5HP 5HP 7 5 HP 7 5HP 11 Tank P05767D P14130D P05767D P14130D P05767D P14130D P05763D P14130D P05763D 12 Isolation Valve CQM3756 CQM3756 CQM3756 CQM3756 CQM3756 CQM3756 CQM3756 CQM3756 CQM3756 13 Pulley 125PSIG P...

Page 26: ...95C P09195C P09195C 4 Motor 2 HP 3 HP 5 HP 7 5 HP 5 Pulley 125 PSIG P12213A CC1005979 P11870C P13912A PULLEY PULLEY PULLEY P09423A P08136A P05607A BUSHING BUSHING BUSHING 5 Pulley 175 PSIG P13197A P07986A M7009D P13912A PULLEY PULLEY PULLEY P11520A P08136A P05607A BUSHING BUSHING BUSHING 6 Belts 5L680 2 5L650 2 5L680 2 B68 2 NOTE 2 HP UNITS WITH SINGLE PHASE MOTOR USE PULLEY P12213A 125 PSIG P1319...

Page 27: ...Ferrule SE542 1 12 Compression Nut SE541 1 Repair Parts List Air Cooled Aftercooler Ref No Description Part Number Qty 13 Discharge Tube Lower 30GH P10705B 1 Discharge Tube Lower 60 80 120GH P10144B 1 Discharge Tube Lower 250GH M2474 1 5 FT Discharge Tube Lower 60 120GV P10422B 1 Discharge Tube Basemount P10143B 1 Discharge Tube Lower 80 GV CC1055732 1 14 Elbow Tube M2398 1 15 Street Elbow Horizon...

Page 28: ... 10 Pipe cap M461 1 11 Governor housing gasket set includes 11A 11B 11C 11D Z130 1 11A Governor housing gasket 032 Thick SE1430 1 11B Governor housing gasket 005 007 Thick SE1430A 1 11C Governor housing gasket 010 Thick SE1430B 1 11D Governor housing gasket 015 Thick SE1430C 1 12 Governor housing NR80A 1 13 Hex head cap screw M2343 4 14 Governor housing cover gasket SE1489 1 15 Baffle plate NR104 ...

Page 29: ...1583 4 40 Piston pin bearing R1037 2 41 Low pressure piston with pin includes items 43 44 ZR154 1 42 High pressure piston with pin includes items 43 44 ZP02709C 1 43 Piston pin R1021 2 44 Piston pin retaining ring R10102 4 45 Low pressure piston ring set Z798 1 46 High pressure piston ring set Z797 1 47 Cylinder P12237D 1 48 Hex head cap screw M2345 6 49 Low pressure discharge valve assembly Z813 ...

Page 30: ...e disc P13865A 1 84 Intake valve seat P14118B 1 85 Gasket Valve HPIN R10 30 CQP14870A 1 86 Hex head machine screw M3220 1 87 High pressure intake manifold P12302B 1 88 Interstage pressure relief valve M3685 1 89 Intake filter P04999A 1 90 Intake filter element P05050A 1 Complete compressor pump gasket set items 11 14 32 Z764 Low pressure piston kit items 41 45 Z9101 1 High pressure piston kit item...

Page 31: ... No Qty 1 Compression Fitting M2879 1 2 Tube Unloading w Fittings ZSB250A 1 3 Compression Fitting M2864 1 4 Breather Tube w Fitting ZUB375 1 5 Compression Fitting M2864 1 6 Compression Fitting 86A40 1 7 Intercooler w Fittings Z9140 1 8 Compression Nut VP1061773 1 C420 B Ref Drawing ...

Page 32: ...3A P02547A Z4877 P09085A P09084A P09086A P09083A 1 1 1 1 1 1 1 1 1 1 High Pressure REF NO DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 10 11 HP Intake Manifold Goup Includes items 1 2 3 4 10 HP Intake Manifold Cylinder Unloader Piston O Ring HP Valve Assembly includes 6 7 8 9 11 Unloader Finger Unloader Spring Locknut Guide System Cylinder Gasket Valve Gasket not included Z9143 P12304B P02306B P09923...

Page 33: ... 11a NOT USED 11b DECAL Synthetic or Food Grade Inserts 12 NOT USED 13 DECAL Pressure Setting 95 125 PSIG 14 DECAL Pressure Setting 140 175 PSIG 14 NOTICE Read and Retain Manuals 15 NOT USED 16 DECAL Rotation Direction 17 NOT USED 18 DECAL Pressure Switch P14677A PUMP HAZARD DECAL LISTING PAGE DESCRIPTION PART NO 35 PUMP DECAL SHEET MASTER P13805A NOT USED A1 NOTICE Lubricants A2 DECAL Rotation Di...

Page 34: ...34 UNIT HAZARD DECALS ...

Page 35: ...35 PUMP HAZARD DECALS F ...

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 ...