CHAMPION R15B Two Stage Two Cylinder Air Compressors Owner’s Manual

CHAMPION R15B Two Stage Two Cylinder Air Compressors

TWO STAGE/TWO CYLINDER AIR COMPRESSORS & UNITS FEATURING THE R10 & R15 PUMPS

WARNING

• 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.

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 are 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.
For the location of your local authorized Champion Air Compressor distributor, refer to the yellow pages of your phone directory or contact:

Factory

• Champion
• 1301 North Euclid Avenue
• Princeton, IL 61356
• Phone: 815-875-3321
• Fax: 815-872-0421
• E-Mail: Champion@Championpneumatic.com

INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify the Compressor MODEL, HORSEPOWER and SERIAL NUMBER (see nameplate on the 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.

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 the air compressor or unit.

2. For installation, follow all local electrical and safety codes, as well as the National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA).

3. Electric motors must be securely and adequately grounded. This can be accomplished by wiring with a grounded, metal-clad raceway system to the starter; by using a separate ground wire connected to the bare metal of the motor frame; or by other suitable means.

4. Protect the power cable from coming in contact with sharp objects. Do not kink the power cable and never allow the cable to come in contact with oil, grease, hot surfaces, or chemicals.

5. Make certain that the power source conforms to the requirements of your equipment.

6. Pull the main electrical disconnect switch and disconnect any separate control lines, if used, before attempting to work or perform maintenance on the air compressor or unit. “Lockout” or “Tag out” all power sources.

7. Do not attempt to remove any compressor parts without first relieving the entire system of pressure.

8. Do not attempt to service any part while the machine is in operational mode.

9. Do not operate the compressor at pressures over its rating.

10. Do not operate the compressor at speeds over its rating.

11. Periodically check all safety devices for proper operation. Do not change the pressure setting or restrict operation in any way.

12. Be sure no tools, 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 without guards, shields and screens in place.

16. 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 the shut-off valve.

17. Do not operate the compressor in areas where there is a possibility of ingesting flammable or toxic fumes.

18. Be careful when touching the exterior of a recently run motor – it may be hot enough to be painful or cause injury.
    With modern motors, this condition is normal if operated at rated load – modern motors are built to operate at higher temperatures.

19. Inspect unit daily to observe and correct any unsafe operating conditions found.

20. Do not “play around” with compressed air, nor direct air stream at the body, because this can cause injuries.

21. Compressed air from this machine absolutely must not be used for food processing or breathing air without adequate downstream filters, purifiers and controls.

22. Always use an air pressure regulating device at the point of use, and do not use air pressure greater than the marked maximum pressure of attachment.

23. Check hoses for weak or worn conditions before each use and make certain that all connections are secure.

24. Always wear safety glasses when using a compressed air gun.

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.

EXPLANATION OF SAFETY INSTRUCTIONS SYMBOLS AND DECALS

DANGER
Indicates immediate hazards which will result in severe injury or death.
WARNING
Indicates hazards or unsafe practices which could result in severe injury or death.
CAUTION
Indicates hazards or unsafe practices that could result in damage to the Champion compressor or minor injury.
NOTICE
Notice is used to notify people of installation, operation or maintenance information which is important but not hazard-related.

OBSERVE, UNDERSTAND AND RETAIN THE INFORMATION GIVEN IN THE SAFETY PRECAUTION DECALS AS SHOWN IN THE PARTS LIST SECTION

DANGER
This reciprocating compressor must not be used for breathing air. To do so will cause serious injury whether air is supplied directly from the compressor source or to breathing tanks for later use. 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.
WARNING
The use of this compressor as a booster pump and/or to compress a medium other than atmospheric air is strictly non-approved and can result in equipment damage and/or injury. Nonapproved uses will also void the warranty.
CAUTION
This unit may be equipped with special options which may not be included in this manual. Users must read, understand and retain all information sent with special options.

INTRODUCTION

Champion R Series compressor 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.

WARRANTY

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 sixty (60) months from the date of installation or sixty-six (66) months from the 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 the 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 twelve (12) months from the date of installation or eighteen (18) months from the 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 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 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 THE CHAMPION HAS THE AUTHORITY TO MAKE ANY WARRANTIES.

TWO-STAGE AIR COMPRESSORS – MODELS R10D & R15B

DIMENSIONS

C416-B (Ref. Drawing)

NOTE: H.P. Exhaust Opening 3/4″ Tubing.
Flywheel Rotation – Clockwise when viewed from front, flywheel to rear.

SPECIFICATIONS

MODEL

| BORE & 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 AIRFLOW CFM| HEAT REJECTION 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| 625| 3360| 5.25
R10D| 125| 2| 760| 14.8| 875| 4480| 7.35
R10D| 175| 2| 725| 14.1| 835| 4480| 7.00
R15B| 125| 3| 490| 14.5| 565| 6700| 4.75
R15B| 175| 3| 440| 12.8| 505| 6700| 4.31
R15B| 125| 5| 750| 21.9| 868| 12,000| 7.35
R15B| 175| 5| 710| 20.7| 820| 12,000| 7.00
R15B| 175| 7-1/2| 990| 28.7| 1195| 16,800| 9.75

• All data is based on 1725 RPM electric motors as a power source.
• Pulley Dia. (approx.) = Compressor RPM x Flywheel Dia.
• Motor or Engine RPM

INSTALLATION

WARNING
Do not operate the 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 the compressor receives an 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 are done.
   Abrasive particles or paint, found to have clogged the air intake filters and intake valves, shall automatically void the warranty.

2. Compressors should never be located so close to a wall or other obstruction that the flow of air through the fan-bladed flywheel, which cools the compressor, is impeded. Permanently mounted units should have a flywheel at least 12″ from the wall.

3. Place stationary compressors on firm-level ground or flooring. Permanent installations require bolting to the floor. Bolt holes in the tank or base feet are provided. Before bolting or lagging down, shim compressor level.
   Avoid putting stress on a tank foot by pulling it down to the floor. This will only result in abnormal vibration and possible cracking of Air Receiver. It is recommended that optional vibro-isolator pads be installed on the unit. Tanks bolted directly to a concrete floor without padding will not be warranted against cracking.
   Champion vibro-isolators must be used for an 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 controls. Controls could be a pressure switch for start/stop operation or a pilot valve for continuous operation. If a pilot valve is used, the compressor must be equipped with head unloaders. Control air must be piped from the air receiver to the pilot valve.

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.

DANGER
Do not install isolating valves between the compressor outlet and air receiver. This will cause excessive pressure if the valve is closed, and cause injury and equipment damage.
WARNING
Always use an air pressure regulating device at the point of use. Failure to do so can result in injury or equipment damage.
CAUTION

• Do not install in an area where the ambient temperature is below 32 degrees F or above 100 degrees F.
• Do not install a unit in an area where the air is dirty and/or chemical-laden.
• The unit is not to be installed outdoors.

ELECTRICAL POWER SUPPLY
It is essential that the power supply and the supply wiring are adequately sized and that the voltage corresponds to the unit specifications. Branch circuit protection must be provided at installation as specified in the National Electrical Code.
All wiring should be performed by a licensed electrician or electrical contractor. Wiring must meet applicable codes for an area of installation. The table gives recommended wire sizes based on the 1999 NEC.

WIRE SIZE (AWG) – 75°C COPPER – 30°C AMBIENT

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 1-1 for the simplex wiring diagram and Figure 1-2 for the duplex wiring diagram.
• If ordered with a factory-mounted magnetic starter, the compressor is wired at the factory. It is necessary only to bring
• lines from a properly sized disconnect switch to the magnetic starter mounted on the unit.

INSTALLATION (CONT’D)

CAUTION
Wiring must be such that when viewing the compressor from the opposite shaft end, the rotation of the shaft is clockwise as shown by an arrow on guard. Wrong-direction rotation for any length of time will result in damage to the 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.
AIR LINE PIPING
Connection to the air system should be of the same size, or larger, than the discharge pipe out of the unit. The table gives recommended minimum pipe sizes. A union connection to the unit and water drop leg is recommended. Install a flexible connector between the discharge of the unit and the plant air piping. Plant air piping should be periodically inspected for leaks using a soap and water solution for detection on all pipe joints. Air leaks waste energy and are expensive.

Minimum Pipe Sizes For Compressor Air Lines (Based on clean Smooth Schedule 40 Pipe)

WARNING
Never use plastic pipe or improperly rated metal pipe. Improper piping material can burst and cause injury or 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. This compressor has been designed for an 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 pressure falls below the cut-in pressure setting of the pressure switch the compressor will run until the cut-out pressure setting of the pressure switch has been reached.
• Duplex units have lead and lag pressure switches and an automatic alternating system to evenly distribute the load between the two compressors. The pressure switches sense changes in receiver pressure and automatically start and stop the compressor at preset pressure levels. If the receiver pressure falls below the cut-in pressure setting of the lead pressure switch but remains above the cut-in pressure setting of the lag pressure switch, only one compressor will run until the receiver pressure reaches the cut-out pressure of the lead pressure switch. The next time the pressure in the receiver drops, the system automatically starts the idle compressor. If the receiver pressure falls below the cut-in pressure setting of the lag pressure switch, both compressors run until the receiver pressure reaches the cut-out pressure setting of the lead pressure switch.

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 the unit in a continuous run, open the needle valve located next to the pilot valve. The pilot valve is now able to sense receiver pressure. When the receiver pressure reaches the cut-out pressure setting of the pilot valve, the pilot valve opens and air is released to the unloader mechanism. The compressor stops compressing air and runs unloaded until the cutin pressure setting of the pilot valve has been reached. At this time air is released from the unloader mechanism and the compressor starts compressing again. A continuous run is recommended if the motor starts exceed 8 starts/hour.

Initial Start-Up

1. Inspect the unit for any visible signs of damage that would have occurred in shipment or during installation.

2. Pull the main disconnect switch to the unit to ensure 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 the compressor on a voltage other than that specified on the order or the compressor motor.

3. Check compressor oil level. Add oil as required. See the “Compressor Oil Specifications” Section.
   NOTE: Do not mix oil type, weights or brands.

4. Activate the main disconnect switch.

5. “Jog” motor and check for proper rotation by direction arrow. If rotation is wrong, reverse input connections on the magnetic starter.

6. Close the receiver outlet hand valve and start.

7. With the receiver, and hand valve closed, let the machine pump up to operating pressure. At this stage, the automatic controls will take over. Check for proper cycling operation.

8. Check for proper operation of any options. Refer to the individual option instruction sheet.

9. When the initial run period has shown no operating problems, shut the unit down and recheck the oil level.

10. Open receiver hand valve. The air compressor unit is now ready for use.

WARNING
This unit can start automatically without warning.

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 the “off” position to ensure no power is entering the unit. “Lock Out” or “Tag Out” all sources of power. Be sure all air pressure in the unit is relieved. Failure to do this may result in injury or equipment damage.

DAILY MAINTENANCE

1. Check the oil level of both compressor and engine if so equipped. Add quality lubricating oil as required. See the Section on “Oil Specifications”.
2. Drain moisture from the tank by opening the tank drain valve located at the bottom of the tank. Do not open the drain valve if tank pressure exceeds 25 PSIG.
3. Turn off the compressor at the end of each day’s operation. Turn off the power supply at the wall switch.

WEEKLY MAINTENANCE

1. Clean dust and foreign matter from the cylinder head, motor, fan blade, airlines, 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 solvents.

3. Check V-belts for tightness. The V-belts must be tight enough to transmit the necessary power to the compressor. Adjust the V-belts as follows:

   • Remove bolts and guards to access the compressor drive.
   • Loosen mounting hardware which secures motor to base. Slide the motor within slots of the baseplate to the desired position.
   • Apply pressure with a finger to one belt at the midpoint span. Tension is correct if the top of the belt aligns with the bottom of the adjacent belt. Make further adjustments if necessary.
   • Check the alignment of pulleys. Adjust if necessary.
   • Tighten mounting hardware to secure the motor on the base.
   • Re-install the guard and secure it with bolts.

WARNING
Never operate the unit without a belt guard in place. Removal will expose rotating parts which can cause injury or equipment damage.

EVERY 90 DAYS OR 500 HOURS MAINTENANCE

1. Change crankcase oil. Use type and grade oil as specified in the section on “Compressor Oil Specifications”.

2. Check the entire system for air leakage around fittings, connections, and gaskets, using soap solution and brush.

3. Tighten nuts and capscrews as required.

4. Check and clean compressor valves, and replace springs, discs and seats when worn or damaged.
   CAUTION
   Valves must be reinstalled in the original position. Valve gaskets should be replaced each time valves are serviced.

5. Pull the ring on all pressure relief valves to ensure proper operation.

GENERAL MAINTENANCE NOTES
PRESSURE RELIEF VALVE: The pressure relief valve is an automatic pop valve. Each valve is properly adjusted for the maximum pressure permitted by tank specifications and the working pressure of the unit on which it is installed. If it should pop, it will be necessary to drain all the air out of the tank to reseat properly. Do not readjust.

TANK DRAIN VALVE: The drain valve is located at the bottom of the tank. Open the drain valve daily to drain condensation.
Do not open the 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 the compressor at low pressure and stop when the maximum pressure is reached. It is adjusted to start and stop the compressor at the proper pressure for the unit on which it is installed. Do not readjust.
BELTS: Drive belts must be kept tight enough to prevent slipping. If belts slip or squeak, see V-belt maintenance in the preceding section.

CAUTION
If belts are too tight, overload will be put on the motor and motor bearings.
COMPRESSOR VALVES: If the compressor fails to pump air or seems slow in filling up the tank, disconnect the unit from a power source remove valves and clean thoroughly, using compressed air and a soft wire brush. After cleaning exceptional care must be taken that all parts are replaced in the same position and all joints must be tight or the compressor will not function properly. When all valves are replaced and connections tight, close the hand valve at the tank outlet for the final test. Valve gaskets should be replaced each time valves are removed from the pump.

CENTRIFUGAL UNLOADER AND UNLOADER PRESSURE RELEASE VALVE:
The centrifugal unloader is operated by two governor weights. It is enclosed and lubricated from the crankcase of the compressor. When the 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. This prevents overloading the motor when starting. If air continues to escape through the governor or unloader pressure release valve while operating, this is an indication that the unloader pressure release valve is not closing tightly and may be held open by the foreign substance that has lodged on the seat. To correct this, remove the governor release valve cap, giving access to the unloader pressure release valve spring and ball. Clean thoroughly and return parts in the same order in which they were removed. Loose drive belts can also cause the unloader to leak by preventing the compressor from reaching the proper speed. (See “BELTS” above).
CHECK VALVE: The check valve closes when the compressor stops operating, preventing air from flowing out of the tank through the pressure release valve. After the compressor stops operating, if air continues to escape through the release valve, it is an indication that the check valve is leaking. This can be corrected by removing the check valve and cleaning the disc and seat. If a check valve is worn badly, replace same.

WARNING
Before removing check valve be sure all air is drained out of the tank and the 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 overpressure and is factory set for a maximum pressure of 75 PSIG. DO NOT RESET If the pressure relief valve pops, it indicates trouble. Shut down the unit immediately and determine and correct the malfunction. Inspect the head valves. Serious damage can result if not corrected and can lead to destruction of the unit. Tampering with the interstage pressure relief valve, or plugging the opening destroys the protection provided and voids all warranty.
COMPRESSOR LUBRICATION: Fill the crankcase to the proper level as indicated by the oil sight gauge. Keep crankcase filled as required by usage. It is recommended that only Champlub recip lubricant be used. This is a 30-weight, non-detergent industrial oil with rust and oxidation inhibitors specially formulated for reciprocating compressors. Do not mix oil types, weights or brands.
MOTOR LUBRICATION : Long-time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. Bearing grease will lose its lubricating ability over time, not suddenly. Refer to the motor manufacturer’s instructions for the type of grease and lubrication intervals.
PILOT VALVE: The pilot valve actuates the head unloader mechanism to provide a means of stopping or starting the compression of air by the compressor without stopping or starting the electric motor.

COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT
Proceed with the following instructions while the compressor is running:

1. Loosen locknut (4) and back off several turns. Do not turn differential pressure adjustment nut (3).
2. Check the reading on the tank pressure gauge. Set the compressor maximum pressure by turning the threaded cap (1) clockwise to increase pressure or counterclockwise to decrease pressure. The pressure setting must be 5 psig less than the setting of the pressure switch.
3. After the pressure is set, tighten the locknut (4). Be careful not to move the threaded cap (1).

COMPRESSOR PILOT VALVE DIFFERENTIAL PRESSURE ADJUSTMENT
Proceed with the following instructions while the compressor is running:

1. Loosen locknut (2) and back off several turns.
2. Check the reading on the tank pressure gauge. Set the pressure to 30 psig differential (unload at 170 psig, reload at 140 psig). Turn nut (3) clockwise to increase differential pressure or counterclockwise to decrease differential pressure.
3. After the pressure is set, tighten the locknut (2). Be careful not to move the nut (3).

COMPRESSOR OIL SPECIFICATIONS

Compressors are factory-filled with CHAMPLUB hydrocarbon-based recip lubricant. This is an ISO 100 nondetergent industrial lubricant with rust and oxidation inhibitors specially formulated for reciprocating compressors. It is recommended this compressor be maintained using this oil for ambient temperatures above 32°F.
CHAMPLUB synthetic is a premium grade diester-based synthetic lubricant providing excellent performance in high-temperature applications.

CAUTION
Do not mix oil types, weights or brands.
CAUTION
“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. The normal break-in period of Champion air compressors is 25 hours.
2. For the first 100 hours of compressor operation, a careful and regular check of the oil level should be made. Maintain the 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. The compressor must run for a 25-hour break-in period using ChampLub ISO 100 oil.
2. Thoroughly drain existing oil from the crankcase.
3. Fill crankcase with a full charge of synthetic lubricant.
4. Run compressor for 200 hours.
5. Stop the compressor and thoroughly drain the synthetic lubricant.
6. Add a full charge of synthetic lubricant.
7. The compressor is now ready to run for an extended period before the next lubricant change. made. Maintain the oil level at the full line.

LUBRICANT

TORQUE VALVES

TROUBLESHOOTING CHART FOR COMPRESSOR

WARNING

• Always disconnect the unit from the power supply and relieve all pressure from the 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.
• Never operate the unit without a belt guard in place.
• Never use gasoline or flammable solvents on or around the compressor unit. Explosion may result.

Troubleshooting Chart

2.         Starter heater coils open.

3.         Starter tripped

4.         Defective pressure switch- contacts will not close

5.         Low voltage.

| 1.           Check all fuses and switches. Check for loose or faulty wires.

2.           Check the overload relay in the starter. Reset starter.

3.           Reset starter. If the starter trips repeatedly, have the electrical system inspected by an electrician.

4.    Repair or replace the pressure switch.

Warning – Relieve tank pressure before servicing.

5.           Check with voltmeter. Be sure the voltage corresponds to unit specifications.

Starter trips repeatedly.| 1.         Improperly adjusted pressure switch.

2.         Faulty check valve.

3.         Incorrect fuse size or magnetic starter heaters.

4.         Low voltage.

5.         Defective motor.

| 1.           Adjust or replace.

Warning – Relieve tank pressure before servicing.

2.           Clean or replace

Warning – Relieve tank pressure before servicing.

3.           Be sure that fuses and heaters are properly rated.

4.           Check with voltmeter. Be sure the 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 the tank.| 1. Drain tank.
The discharge pressure relief valve pops off while the compressor is running.| 1.         Wrong pressure switch setting.

2.         Defective ASME relief valve.

| 1.        Adjust to the correct setting.

2.        Replace valve.

  Warning – Relieve tank pressure

before servicing.

The compressor will not unload (Units with head unloaders)| 1.         Wrong pilot valve setting.

2.         Defective pilot valve.

3.         Lack of air to the pilot valve.

| 1.           Adjust to the correct setting

2.           Replace the pilot valve.

3.           Open the needle valve to the pilot valve.

Excessive belt wear.| 1.         Pulley out of alignment.

2.         Belts are too tight or too loose.

| 1.           Realign motor pulley.

2.           Adjust belt tension.

The compressor runs hot.| 1.         Improper flywheel rotation

2.         Defective compressor valves.

3.         Dirty air filter.

4.         Dirty cylinder and/or intercooler.

| 1.           Check for correct rotation. (Counterclockwise when viewed from the drive side.

2.           Install new valve plate assembly.

3.           Clean or replace.

4.           Clean cylinder fins and/or intercooler.

The interstage pressure relief valve pops off.| 1.      Defective compressor valves.| 1.       Install new valves.
Excessive oil consumption.| 1.         Dirty air filter.

2.         Wrong oil viscosity.

3.         Oil leaks.

4.         Worn piston rings.

5.         Scored cylinder

| 1.           Clean or replace.

2.           Refill with proper viscosity oil.

3.           Tighten bolts. Replace gaskets.

4.           Replace rings.

5.           Replace cylinder.

replace valve
Air escapes from the centrifugal unloader when the unit is stopped.| 1. Check the valve stuck in the open position.| 1.       Replace check valve.

  Warning – Relieve tank pressure before servicing.

The system does not alternate| 1.      Starter tripped.| 1.           Reset starter. If the starter trips repeatedly, have the electrical system inspected by an electrician.

2.           Check and tighten all wiring connections.

3.           Replace alternator.

4.           Replace motor.

(Duplex units only)|
 | 2.      Loose wiring in alternator.
 | 3.      Defective alternator.
 | 4.      Defective motor.

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

REPAIR PARTS LIST
MODELS

P14202A
8. Pressure Relief Valve| M2843| M2843| M2843| M2843| M2843| M2843| M2843| M2843
9. Motor| 1-1/2 HP| 1-1/2 HP| 1-1/2 HP| 2 HP| 2 HP| 2-HP| 3 HP| 3HP
10. Tank| P04390D| P01136D| P01164D| P04390D| P01136D| P01164D| P04390D| P01136D
11. Isolation Valve| M3590| M3590| M3590| M3590| M3590| M3590| M3590| M3590

*12. Pulley

|

125 PSIG

|

P08509A

|

P08509A

|

P08509A

| P07986A PULLEY P11658A

BUSHING

| P07986A PULLEY P11658A

BUSHING

| P07986A PULLEY P11658A

BUSHING

|

P11121B

|

P11121B

*12. Pulley

|

175 PSIG

|

P09315B

|

P09315B

|

P09315B

| P11703A PULLEY P09423A

BUSHING

| P11703A PULLEY P09423A

BUSHING

| P11703A PULLEY P09423A

BUSHING

|

M4309D

|

M4309D

13. Belts| 4L650 (2)| 4L650 (2)| 4L650 (2)| 5L680 (2)| 5L680 (2)| 5L680 (2)| 5L650 (2)| 5L650 (2)
 | HR3-8| HR3-12| HR5-3| HR5-6| HR5-8| HR5-12| HR7F-6| HR7F-8| HR7F-12
---|---|---|---|---|---|---|---|---|---
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 (Standard)| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936
3. Belt Guard (With ACAC)| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937
4. Drain Valve| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988
5. Check Valve| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A
7. Pressure Switch| 125 PSIG| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A
175 PSIG| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A
8. Pressure Relief Valve| M2843| M2843| M2843| M2843| M2843| M2843| M2843| M2843| M2843
9. Motor| 3 HP| 3 HP| 5 HP| 5 HP| 5 HP| 5 HP| 7.5 HP| 7..5 HP| 7.5 HP
10. Tank| P01164D| P01596D| P04390D| P01136D| P01164D| P01596D| P01136D| P01164D| P01596D
11. Isolation Valve| M3590| CQM3756| M3590| M3590| M3590| CQM3756| M3590| M3590| CQM3756

*12.Pulley

| ****

125PSIG

| ****

P11121B

| ****

P11121B

| ****

P11870C

| ****

P11870C

| ****

P11870C

| ****

P11870C

| P13912A PULLEY P05607A

BUSHING

| P13912A PULLEY P05607A

BUSHING

| P13912A PULLEY P05607A

BUSHING

*12.Pulley

| ****

175 PSIG

| ****

M4309D

| ****

M4309D

| ****

M7009D

| ****

M7009D

| ****

M7009D

| ****

M7009D

| P13912A PULLEY P05607A

BUSHING

| P13912A PULLEY P05607A

BUSHING

| P13912A PULLEY P05607A

BUSHING

13. Belts| 5L650 (2)| 5L650 (2)| 5L680 (2)| 5L680 (2)| 5L680 (2)| 5L680 (2)| B68 (2)| B68 (2)| B68 (2)

NOTE: 2 HP UNITS WITH SINGLE PHASE MOTOR USE:
PULLEY: P11870C (125 PSIG); M7009D (175PSIG) BELTS: 5L680 (2)

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

REPAIR PARTS LIST
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
---|---|---|---|---|---|---|---|---|---|---|---|---|---
1. Pump| R10D| R10D| R10D| R10D| R15B| R15B| R15B| R15B| R15B| R15B| R15B| R15B| R15B
2. Pressure Gauge| M519C| M519C| M519C| M519C| M519C| M519C| M519C| M519C| M519C| M519C| M519C| M519C| M519C
3. Belt Guard (Standard)| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936| CC1060936
3. Belt Guard (With ACAC)| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937
4. Drain Valve| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988
5. Check Valve| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A
7. Pressure Switch| 125 PSIG| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A
175 PSIG| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| P14202A| 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| CC1048923| P01161D| CC1048923| P01161D| CC1048923| P02212D| P01161D| CC1048923| P02212D| P01161D| CC1048923| P02212D
11. Isolation Valve| M3590| M3590| M3590| M3590| M3590| M3590| CQM3756| M3590| M3590| CQM3756| M3590| M3590| CQM3756

*12. Pulley

| ****

125PSIG

| ****

P08509A

| ****

P08509A

| P07986A PULLEY P11658A

BUSHING

| P0786A PULLEY P11658A

BUSHING

| ****

P11121B

| ****

P11121B

| ****

P11121B

| ****

P11870C

| ****

P11870C

| ****

P11870C

| P13912A PULLEY P05607A

BUSHING

| P13912A PULLEY P05607A

BUSHING

| P13912A PULLEY P05607A

BUSHING

*12. Pulley

| ****

175 PSIG

| ****

P09315B

| ****

P09315B

| P11703A PULLEY P09423A

BUSHING

| P11703A PULLEY P09423A

BUSHING

| ****

M4309D

| ****

M4309D

| ****

M4309D

| ****

M7009D

| ****

M7009D

| ****

M7009D

| P13912A PULLEY P05607A

BUSHING

| P13912A PULLEY P05607A

BUSHING

| P13912A PULLEY P05607A

BUSHING

13. Belts| 4L650 (2)| 4L650 (2)| 5L680 (2)| 5L680 (2)| 5L650 (2)| 5L650 (2)| 5L650 (2)| 5L680 (2)| 5L680 (2)| 5L680 (2)| B68 (2)| B68 (2)| B68 (2)

NOTE: 2 HP UNITS WITH SINGLE PHASE MOTOR USE:
PULLEY: P11870C (125 PSIG); M7009D (175PSIG) BELTS: 5L680 (2)

UNIT REPAIR PARTS ILLUSTRATION
MODELS: HR2D-8, HR2D-12, HR3D-8, HR3D-12 HR5D-8, HR5D-12, HR7DF-12 & HR7DF-25

REPAIR PARTS LIST
MODELS

 | HR2D-8| HR2D-12| HR3D-8| HR3D-12| HR5D-8| HR5D-12| HR5D-25| HR7DF-12| HR7DF-25
---|---|---|---|---|---|---|---|---|---
1. Pump| R10D| R10D| R15B| R15B| R15B| R15B| R15B| R15B| R15B
2. Pressure Gauge| M519C| M519C| M519C| M519C| M519C| M519C| M519C| M519C| M519C
3. Belt Guard (Standard)| CC1060945| CC1060936| CC1060945| CC1060936| CC1060945| CC1060936| CC1060936| CC1060936| CC1060936
3. Belt Guard (With ACAC)| CC1060947| CC1060937| CC1060947| CC1060937| CC1060947| CC1060937| CC1060937| CC1060937| CC1060937
4. Belt Guard (Standard)| CC1060946| CC1060954| CC1060946| CC1060954| CC1060946| CC1060954| CC1060954| CC1060954| CC1060954
4. Belt Guard (With ACAC)| CC1060948| CC1060955| CC1060948| CC1060955| CC1060948| CC1060955| CC1060955| CC1060955| CC1060955
5. Drain Valve| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988| VP1022988
6. Check Valve| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A| P05822A

8. Pressure Switch

| 125

PSIG

| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A| P14205A
175

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
 |  | P07986A (2)| P07986A (2)|  |  |  |  |  | P13912A (2)| P13912A (2)
*13. Pulley| 125PSIG| PULLEY

P11658A (2)

| PULLEY

P11658A (2)

| P11121B (2)| P11121B (2)| P11870C (2)| P11870C (2)| P11870C (2)| PULLEY

P05607A (2)

| PULLEY

P05607A (2)

 |  | BUSHING| BUSHING|  |  |  |  |  | BUSHING| BUSHING
 |  | P11703A| P11703A|  |  |  |  |  | P13912A| P13912A
 |  | (2)| (2)|  |  |  |  |  | (2)| (2)
*13. Pulley| 175| PULLEY| PULLEY| M4309D (2)| M4309D (2)| M7009D (2)| M7009D (2)| M7009D (2)| PULLEY| PULLEY
 | PSIG| P09423A| P09423A|  |  |  |  |  | P05607A| P05607A
 |  | (2)| (2)|  |  |  |  |  | (2)| (2)
 |  | BUSHING| BUSHING|  |  |  |  |  | BUSHING| BUSHING
14. Belts| 5L680 (4)| 5L680 (4)| 5L650 (4)| 5L650 (4)| 5L680 (4)| 5L680 (4)| 5L680 (4)| B68 (4)| B68 (4)
15. Starter| CONSULT FACTORY
16. Alternator| CONSULT FACTORY

NOTE: 2 HP UNITS WITH SINGLE PHASE MOTOR USE:
PULLEY: P11870C (125 PSIG); M7009D (175PSIG) BELTS: 5L680 (4)

UNIT REPAIR PARTS ILLUSTRATION
MODELS: BR-1, BR-2, BR-3, BR-5 & BR-7F

REPAIR PARTS LIST
MODELS

CC1060936
2. Belt Guard (With ACAC)| CC1060937| CC1060937| CC1060937| CC1060937| CC1060937
3. Base Plate| P09195C| P09195C| P09195C| P09195C| P09195C
4. Motor| 1.5 HP| 2 HP| 3 HP| 5 HP| 7.5 HP

*5. Pulley

|

125 PSIG

|

P08509A

| P07986A PULLEY P11658A

BUSHING

|

P11121B

|

P11870C

| P13912A PULLEY P05607A

BUSHING

*5. Pulley

|

175 PSIG

|

P09315B

| P11703A PULLEY P09423A

BUSHING

|

M4309D

|

M7009D

| P13912A PULLEY P05607A

BUSHING

6. Belts| 4L650 (2)| 5L680 (2)| 5L650 (2)| 5L680 (2)| B68 (2)

REPAIR PARTS ILLUSTRATION
AIR-COOLED AFTERCOOLER

Repair Parts List Air Cooled Aftercooler

Ref. No. Description Part Number Qty.

1. Afterciootiler PP14t4N77Bb 1

2. Belt Guard, Aftercooler P14072C 1

3. Clip P10005A 4

4. Isolators M1367 4

5. Bracket, ACAC CC1055729 1

6. Screw M2627 2

7. Nut M3485 2

8. Screw M1454 4

9. Compression Elbow M2288 2

10. Discharge Tube, Upper P10143B 1

11. Compression Ferrule SE542 1

12. Compression Nut SE541 1

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, Horizontal Units Only M1296 1

16. Nipple, Horizontal Units Only M1035B 1

17. Check Valve P05822A 1

18. Compression Fitting M2350 1

19. Compression Fitting M2867 1

20. Bracket, Coupling CC1032600 1

21. Nut M3424 2

22. Screw M3471 2

Compressor Repair Parts Illustration
Models: R10D & R15B

Ref. No. Description Part No. Qty.

1. Crankcase M1820 1
2. Pipe plug 64AA5 1
3. Key U8 1
4. Flywheel NR7A 1
5. Hex head cap screw M738 1
6. Hex nut M2955 1
7. Pipe plug 64A5 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
12. A Governor housing gasket (.032” Thick) SE1430 1
13. B Governor housing gasket (.005/.007” Thick) SE1430A 1
14. C Governor housing gasket (.010” Thick) SE1430B 1
15. D Governor housing gasket (.015” Thick) SE1430C 1
16. Governor housing NR80A 1
17. Hex head cap screw M2343 4
18. Governor housing cover gasket SE1489 1
19. Baffle plate NR104 1
20. Governor weight spindle SE583B 1
21. Governor weight SE582B 2
22. Governor weight pin SE592A 1
23. Lock washer M3468 1
24. Hex head cap screw M2345 1
25. Flat washer M912A 1
26. Governor spring SE590 1
27. Spring sleeve SE587 1
28. Governor housing cover RE10100A 1
29. Unloader muffler assembly Z4593 1
30. Hex head machine screw M3473 6
31. Release valve assembly Z12414A 1
32. Release valve plunger SE586B 1
33. Release valve ball P07841A 1
34. Release valve spring SE591 1
35. Release valve body NR101 1
36. Cylinder flange gasket NR29A 1
37. Crankshaft (Model R10D) R105 1
38. Crankshaft (Model R15B) R155 1
39. Main Bearing ZNR16 2
40. Oil seal OSN4 1
41. Connecting rod assembly model R10D low pressure (includes items 37 thru 40) Z750 1
42. Connecting rod assembly model R10D high pressure (includes items 37 thru 40) Z752 1
43. Connecting rod assembly model R15B (includes items 37 thru 40) Z750 2
44. Connecting rod (not sold separately) — —
45. Oil dipper (Model R10D) R1025 2
46. Oil dipper (Model R15B) R1524 2
47. Connecting rod bolt M1583 4
48. Piston pin bearing R1037 2
49. Low pressure piston with pin (includes items 43 & 44) ZR154 1
50. High pressure piston with pin (includes items 43 & 44) ZP02709C 1
51. Piston pin R1021 2
52. Piston pin retaining ring R10102 4
53. Low pressure piston ring set Z798 1
54. High pressure piston ring set Z797 1
55. Cylinder P12237D 1
56. Hex head cap screw M2345 6
57. Low pressure discharge valve assembly Z813 1
58. Valve gasket P04135A 1
59. Discharge valve seat M2097 1
60. Valve disc RE1061 1
61. Valve spring RE1059 1
62. Discharge valve cage M2099 1
63. Valve gasket P04135A 1
64. Hex head machine screw M3220 1
65. Low pressure discharge manifold RE102E 1
66. Ferrule SE542 3
67. Compression nut SE541 3
68. Hex head cap screw P05005A 8
69. High pressure discharge valve assembly Z115 1
70. Valve gasket P04137A 1
71. Discharge valve seat RE757A 1
72. Valve disc RE1062 1
73. Valve spring RE760 1
74. Hex head machine screw M3220 1
75. Gasket, Valve, HPEX, R10-30 CQP14869A 1
76. Discharge valve cage M2100 1
77. High pressure discharge manifold (Non-Base Mount Units) P12303B 1
78. High pressure discharge manifold (Base Mount Units) M1717 1
79. Pressure relief valve P09704A 1
80. Low pressure intake valve assembly Z812 1
81. Gasket, Valve, LPIN, R10-30 CQP14832A 1
82. Intake valve cage M2098 1
83. Valve spring RE1458 1
84. Valve disc RE1470 1
85. Intake valve seat RE1471 1
86. Hex head machine screw P04544A 1
87. Low pressure intake manifold P09669C 1
88. High pressure intake valve assembly Z11937 1
89. Valve gasket P09171A 1
90. Intake valve cage P14224B 1
91. Valve spring P13866A 2
92. Valve disc P13865A 1
93. Intake valve seat P14118B 1
94. Gasket, Valve, HPIN, R10-30 CQP14870A 1
95. Hex head machine screw M3220 1
96. High pressure intake manifold P12302B 1
97. Interstage pressure relief valve M3685 1
98. Intake filter P04999A 1
99. 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
• Complete compressor pump ring set (items 45 & 46) Z799 1
• Complete valve set w/gaskets Z5155 1
• Complete valve set gaskets Z5156 1
• See page 31 for intake valves for head unloader pumps.
• Use Z6795 – Complete Valve Set for head unloader pumps.

Compressor Repair Parts Illustration
Models: R10D & R15B

Ref. No. Description Part 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 VP106173 1

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.
The parts called out below replace or are substituted for those found in the regular parts list.

Repair Parts List for Constant Speed Head Unloader

Low Pressure

REF. NO.| DESCRIPTION| PART NO.| QTY.
–| LP Intake Manifold Group (includes 1,2,3,4)| Z6312| 1
1| LP Intake Manifold| P09670C| 1
2| Cylinder| P02306B| 1
3| Unloader Piston| P09923A| 1
4| O-Ring| P02547A| 1
5| LP Valve Assembly| Z4877| 1
 | (includes 6,7,8,9)|  |
6| Unloader Finger| P09085A| 1
7| Unloader Spring| P09084A| 1
8| Locknut| P09086A| 1
9| Guide Stem| P09083A| 1
High Pressure
REF. NO.| DESCRIPTION| PART NO.| QTY.
–| HP Intake Manifold Goup| Z9143| 1
 | (Includes items 1,2,3,4,10)|  |
1| HP Intake Manifold| P12304B| 1
2| Cylinder| P02306B| 1
3| Unloader Piston| P09923A| 1
4| O-Ring| P02547A| 1
5| HP Valve Assembly| Z11938| 1
 | (includes 6,7,8,9 & 11)|  |
6| Unloader Finger| P14119A| 1
7| Unloader Spring| P01882A| 1
8| Locknut| P09086A| 1
9| Guide System| P09296A| 1
10| Cylinder Gasket| P00746A| 1
11| Valve Gasket (not included)| P09171A| 1
Low & High Pressure
REF.NO.| DESCRIPTION| PART NO.| QTY.

12

13

14

15

16

17

18

19

20

—

—

| ****

Compression Fitting Manifold Tube Compression Fitting Actuating Tube Pilot Valve Compression Fitting

Screw, Hex Head Cap Mounting bracket Compression Fitting

Needle Valve (Dual Control) Not Shown Constant Speed Head Unloader Kit (Includes all of the above)

| ****

M2879 Z9172 M2868 P12323A M2853 86A40 M3465 M807 M2868

M547 Z9144

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UNIT HAZARD DECAL LISTING

PAGE

34

| DESCRIPTION

PRODUCT LIABILITY DECAL SHEET – MASTER

| PART NO.

P10157A

---|---|---
 | Unit Pressure Setting| 1
 | NOT USED| 2
 | DANGER – Breathing Air| 3
 | DANGER – Drain Tank Daily| 4
 | WARNING – Pressure/Safety Valve| 5
 | NOT USED| 6
 | DANGER – Valve Maintenance| 7
 | DANGER – High Voltage| 8
 | WARNING – Hot Surfaces| 9
 | WARNING – Do Not Remove Fan Guard| 10
 | NOTICE – Lubricant| 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 35| DESCRIPTION

PUMP DECAL SHEET – MASTER

NOT USED

| PART NO. P13805A

A1

---|---|---
 | NOTICE – Lubricants| A2
 | DECAL – Rotation Direction| B
 | NOTICE – Read and Retain Manuals| C
 | DANGER – Breathing Air| D
 | DECAL – Made in the United States of America| E
 | IMPORTANT NOTICE – Motor Burn-Outs| F

DO NOT CONNECT INCOMING POWER SUPPLY TO PRESSURE SWITCH.

UNIT HAZARD DECALS

PUMP HAZARD DECALS

CONTACT

• www.championpneumatic.com
• Champion
• 1301 North Euclid Avenue
• Princeton, Illinois 61356 USA
• Phone 815-875-3321
• Fax 815-872-0421
• 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

References

• IIS7
• Reciprocating & Rotary Screw Compressors- Champion
• Manual-Hub.com – Free PDF manuals!

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