Champion HR2-6, Operation & Maintenance Manual

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 02 01 08 2004 C453 A Ref Drawing C452 A Ref Drawing ...

Page 2: ...orrect 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 b...

Page 3: ...d 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 30 Constant Speed Head Unloader Kit 31 Unit Hazard Decal Tags 32 33 Pump Hazard Decals Tags 34 Record Of Maintenance Service 35 ...

Page 4: ...ration 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 withou...

Page 5: ...N DANGER This reciprocating compressor must not be used for breathing air 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 injury death and or property damage including consequential damages stemming from the use of this compressor to supply breathing air will be discla...

Page 6: ...t 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 MOT...

Page 7: ...CITY 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 REJECTI ON BTU HR APPROX PULLEY O D INCHES R10D 125 1 1 2 570 11 0 660 3360 5 55 R10D 175 1 1 2 542 10 5 ...

Page 8: ...e 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 contro...

Page 9: ...IENT 3 PHASE 1 PHASE MOTOR HP 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 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 C...

Page 10: ...10 INSTALLATION CONT D B1258 A Ref Drawing B1257 A Ref Drawing ...

Page 11: ... property damage OPERATION This compressor 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 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 pressure falls below the cut in...

Page 12: ...t 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 WARNING 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: ... 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 T...

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: ...can be corrected by removing check valve and cleaning disc and seat If check valve is worn badly replace same WARNING 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 pressur...

Page 16: ... 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 re...

Page 17: ...nly 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 compressor for 200 hours 5 Stop compressor and thoroughly drain the synthetic lubricant 6 Add a full charge of synthetic lubricant 7...

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 HR1 3 HR1 6 HR1 8 HR2 3 HR2 6 HR2 8 HR3 3 HR3 6 HR3 8 HR3 12 HR5 3 HR5 6 HR5 8 HR5 12 HR7F 6 HR7F 8 HR7F 12 C454 A Ref Drawing ...

Page 21: ... 2 5L650 2 5L650 2 HR3 8 HR3 12 HR5 3 HR5 6 HR5 8 HR5 12 HR7F 6 HR7F 8 HR5 8 1 Pump R15B R15B R15B R15B R15B R15B R15B R15B R15B 2 Pressure Gauge M519C M519C M519C M519C M519C M519C M519C M519C M519C 3 Belt Guard Z307 Z307 Z307 Z307 Z307 Z307 Z307 Z307 Z307 4 Drain Valve M2684 M2684 M2684 M2684 M2684 M2684 M2684 M2684 M2684 5 Check Valve P05822A P05822A P05822A P05822A P05822A P05822A P05822A P058...

Page 22: ...22 UNIT REPAIR PARTS ILLUSTRATION MODELS VR1 6 VR1 8 VR2 6 VR2 8 VR3 6 VR3 8 VR3 12 VR5 6 VR5 8 VR5 12 VR7F 6 VR7F 8 VR7F 12 A S M E PLATE DATA 5 3 1 13 NOT SHOWN 12 NOT SHOWN 9 10 4 C455 A Ref Drawing ...

Page 23: ...202A P14202A P14202A 8 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 9 Motor 1 1 2 HP 1 1 2 HP 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 P01217D P01161D P01217D P01161D P01217D P02212D P01161D P01217D P02212D P01161D P01217D P02212D 11 Isolation Valve M3590 M3590 M3590 M3590 M3590 M3590 M2686 M3590 M3590 M2686...

Page 24: ...24 UNIT REPAIR PARTS ILLUSTRATION MODELS HR2D 8 HR2D 12 HR3D 8 HR3D 12 HR5D 8 HR5D 12 HR7DF 12 HR7DF 25 C457 A Ref Drawing ...

Page 25: ...4202A 9 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 10 Motor 2 HP 2 HP 3 HP 3HP 5 HP 5 HP 7 5 HP 7 5HP 11 Tank P05767D P14130D P05767D P14130D P05767D P14130D P14130D P05763D 12 Isolation Valve M2686 M2686 M2686 M2686 M2686 M2686 M2686 M2686 P07986A 2 P07986A 2 P07981A 2 P07981A 2 PULLEY PULLEY PULLEY PULLEY P11658A 2 P11658A 2 P05607A 2 P05607A 2 13 Pulley 125PSIG BUSHIN...

Page 26: ...late P09195C P09195C P09195C P09195C P09195C 4 Motor 1 5 HP 2 HP 3 HP 5 HP 7 5 HP P07986A P07981A PULLEY PULLEY P11658A P05607A 5 Pulley 125 PSIG P08509A BUSHING P11121B P11870C BUSHING P11703A P07981A PULLEY PULLEY P09423A P05607A 5 Pulley 175 PSIG P09315B BUSHING M4309D M7009D BUSHING 6 Belts 4L650 2 5L680 2 5L650 2 5L680 2 B68 2 NOTE 2 HP UNITS WITH SINGLE PHASE MOTOR USE PULLEY P11870C 125 PSI...

Page 27: ... 6 Hex nut M2955 1 7 Pipe plug M459 1 8 Oil level gauge RE714 1 9 Pipe nipple M492 1 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 hea...

Page 28: ...ipper Model R15B R1524 2 39 Connecting rod bolt M1583 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 retaing 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...

Page 29: ...sc P13865A 1 84 Intake valve seat P14118B 1 85 Valve gasket P09170A 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 items 42 46 Z9100 Comp...

Page 30: ... PART NO NAME REQ 1 2 3 4 5 6 7 M2868 ZSB250A M2864 ZUB375 M2864 M2881 Z9140 Compression Fitting Tube Unloading w Fittings Compression Fitting Breather Tube w Fittings Compression Fitting Compression Fitting Intercooler w Fittings 1 1 1 1 1 1 1 C420 A Ref Drawing ...

Page 31: ...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 32: ... 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 34 PUMP DECAL SHEET MASTER P13805A NOT USED A1 NOTICE Lubricants A2 DECAL Rotation Di...

Page 33: ...33 UNIT HAZARD DECALS ...

Page 34: ...34 PUMP HAZARD DECALS F ...

Page 35: ...VICE DAILY CHECK OIiL LEVEL DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS MONTHLY INSPECT AIR SYSTEM EVERY 3 MONTHS CHANGE OIL INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 36: ...E mail champion championpneumatic com Plants in Princeton IL and Manteca CA Due to Champion s continuing product development program specifications and materials are subject to change without notice or obligation Copyright 8 2004 Gardner Denver Inc Printed in U S A FOR PARTS REFER TO PARTS DEPOT LIST ACCOMPANYING THIS MANUAL ...