Champion C408-A Operation Maintenance Manual & Parts List Download

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OPERATION/MAINTENANCE

MANUAL & PARTS LIST

TWO STAGE/FOUR CYLINDER AIR COMPRESSORS & UNITS

FEATURING THE R30D PUMP

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 R30D COMPRESSOR

MODEL HR10-12 UNIT

Form No. F3233 Ver: 11 07/01/2009

C408-A
(Ref.

Drawing)

C476-A
(Ref.

Drawing)

Summary of Contents for C408-A

Page 1: ...AINS 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 R30D COMPRESSOR MODEL HR10 12 UNIT Form No F3233 Ver 11 07 01 2009 C408 A Ref Drawing C476 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: ...And Decals 5 Introduction 6 Warranty 6 Dimensions And Specifications 7 Installation 8 9 10 Operation 11 12 Maintenance 12 13 14 15 Compressor Oil Specifications 16 Lubricant 16 Torque Valves 16 Trouble Shooting Guide 17 18 Parts List 19 thru 26 Constant Speed Head Unloader Kit 27 Unit Hazard Decal Tags 28 29 Pump Hazard Decals Tags 30 Record Of Maintenance Service 31 ...

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: ... 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 R30D 4 5 8 2 1 2 x 3 4 4 220 175 0583 400 1050 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 R30D 125 7 1 2 670 39 6 975 16 800 7 00 R30D 175 7 1 2 575 33 5 835 16 ...

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: ...WG 75 C COPPER 30 C AMBIENT 3 PHASE MOTOR HP 200 208V 230V 460V 575V 7 1 2 8 6 10 6 14 10 14 10 10 8 4 8 4 12 8 14 10 15 6 2 6 3 10 6 10 8 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 simplex wiring diagram and Figure 1 2 for duplex wiring diagram If ordered ...

Page 10: ...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 11: ...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 12: ... 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 13: ...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 14: ...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 15: ... 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 16: ...el should 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 ...

Page 17: ...k 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 running 1 Wrong pre...

Page 18: ... 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 connections 3 Repla...

Page 19: ...Z1542 125 PSIG P14205A P14205A P14205A P14205A P14205A P14205A P14205A P14205A 7 Pressure Switch 175 PSIG P14202A P14202A P14202A P14202A P14202A P14202A P14202A P14202A 8 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 9 Motor 7 1 2 HP 7 1 2 HP 10 HP 10 HP 10 HP 15 HP 15 HP 15 HP 10 Tank P01400D P01596D P01400D P01596D P03564D P01400D P01596D P03564D 11 Isolation Valve CQM37...

Page 20: ...A P05822A P05822A P05822A 6 Bucket High Drain Z1541 Z1541 Z1541 Z1541 Z1541 125 PSIG P14205A P14205A P14205A P14205A P14205A 7 Pressure Switch 175 PSIG P14202A P14202A P14202A P14202A P14202A 8 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 9 Motor 7 1 2 HP 7 1 2 HP 10 HP 10 HP 15 HP 10 Tank P05944D P02212D P05944D P02212D P02212D 11 Isolation Valve CQM3756 CQM3756 CQM3756 CQM3756 CQM3756 P11...

Page 21: ... High Drain Z1541 Z1542 Z1541 Z1542 Z1541 Z1542 125 PSIG P14205A P14205A P14205A P14205A P14205A P14205A 8 Pressure Switch 175 PSIG P14202A P14202A P14202A P14202A P14202A P14202A 9 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 M2843 10 Motor 7 1 2 HP 7 1 2 HP 10 HP 10 HP 15 HP 15 HP 11 Tank P14129D P05763D P14129D P05763D P014129D P05763D 12 Isolation Valve CQM3756 CQM3756 CQM3756 CQM3756 C...

Page 22: ...5F 1 Pump R30D R30D R30D 2 Belt Guard CC1010951 CC1010951 CC1010951 3 Base Plate P03970C P03970C P03970C 4 Motor 7 1 2 HP 10 HP 15 HP P11657A P10718A PULLEY PULLEY P05607A P05622A 5 Pulley 125 PSIG M7011D BUSHING BUSHING P10718A PULLEY P05622A 5 Pulley 175 PSIG M2938 M2920 BUSHING 6 Belts B80 2 B81 2 B85 2 C480 A Ref Drawing ...

Page 23: ...1 11 Pipe plug 64A5 1 12 Pipe nipple M492 1 13 Pipe cap M461 1 14 Governor housing gasket set includes 15 16 17 18 Z3030 1 15 Governor housing gasket 032 Thick SE3030 1 16 Governor housing gasket 005 Thick SE3030A 1 17 Governor housing gasket 010 Thick SE3030B 1 18 Governor housing gasket 015 Thick SE3030C 1 19 Governor housing P12273C 1 20 Hex head cap screw M3690 4 21 Governor housing cover gask...

Page 24: ...R1037 4 48 High pressure piston with pin includes items 50 51 ZP02709C 2 49 Low pressure piston with pin includes items 50 51 ZR154 2 50 Piston pin retaing ring R10102 8 51 Piston pin R1021 4 52 Low pressure piston ring set Z798 2 53 High pressure piston ring set Z797 2 54 Intake filter P04999A 2 55 Valve gasket P04135A 2 56 Discharge valve seat M2097 2 57 Valve disc RE1061 2 58 Valve spring RE105...

Page 25: ... 2 87 Low pressure intake manifold P09669C 2 88 High pressure discharge manifold P12303B 2 89 Low pressure discharge manifold RE102E 2 90 Compression nut SE541 6 91 Ferrule SE542 6 92 Hex head cap screw P05005A 16 93 Pressure relief valve P09704A 1 94 Intake filter element P05050A 2 Complete compressor pump gasket set items 3 11 21 Z10887 1 Low pressure piston kit items 49 52 Z9101 2 High pressure...

Page 26: ...ase Valve Tube w Fittings Items 1 3 ZP8133B 1 3 Tube Fitting 86A40 1 4 Tube Fitting M2864 1 5 Breather Tube w Fitting Items 4 6 ZUB375B 1 6 Tube Fitting M2864 1 7 Tube Discharge ZP8132B 1 8 Intercooler Tube w Fittings Z9141 1 9 Intercooler Tube w Fittings Z9142 1 10 Tube Discharge ZM2474 8 1 11 Tube Fitting M2867 2 12 Pipe Tee M480 1 C412 A Ref Drawing ...

Page 27: ...083A 2 2 2 2 2 2 2 2 2 2 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 P09923A P02547A Z11938 P14119A P01882A P09086A P09...

Page 28: ... 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 30 PUMP DECAL SHEET MASTER P13805A NOT USED A1 NOTICE Lubricants A2 DECAL Rotation Di...

Page 29: ...29 UNIT HAZARD DECALS ...

Page 30: ...30 PUMP HAZARD DECALS F ...

Page 31: ...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 32: ...321 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 Copyright 2009 Gardner Denver Inc Printed in U S A F3233VER11 F3233VER11 ...

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