Champion CCE10 Operation Maintenance Manual & Parts List Download Page 3

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TABLE OF CONTENTS

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Subject

Page

Maintain Compressor Reliability And Performance With .................................................. 2

Explanation Of Safety Instructions Symbols And Decals.................................................. 4

Safety And Operation Precautions.................................................................................... 5

Introduction........................................................................................................................ 6

Warranty ............................................................................................................................ 6

Specifications .................................................................................................................... 7

Installation ......................................................................................................................... 8

Operation.................................................................................................................11 & 12

Maintenance......................................................................................................13, 14 & 15

Compressor Pilot Valve Differential Pressure Adjustment.............................................. 16

Parts Replacement Schedule..................................................................................17 & 18

Trouble Shooting Chart ...........................................................................................19 & 20

Unit Repair Parts List ..........................................................................................21 thru 26

Unit Hazard Decal Listing........................................................................................27 & 28

Pump Hazard Decals ...................................................................................................... 29

Record Of Maintenance Service .............................................................................30 & 31

Summary of Contents for CCE10

Page 1: ...UGH 5 HP 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 H3MTOIl 6 Form No F3266 VER 12 07 01 2009 B998 A Ref Drawing ...

Page 2: ... Trained parts specialists to assist you in selecting the correct replacement parts 2 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 by providing fast expert maintenance and repair services For ...

Page 3: ... And Decals 4 Safety And Operation Precautions 5 Introduction 6 Warranty 6 Specifications 7 Installation 8 Operation 11 12 Maintenance 13 14 15 Compressor Pilot Valve Differential Pressure Adjustment 16 Parts Replacement Schedule 17 18 Trouble Shooting Chart 19 20 Unit Repair Parts List 21 thru 26 Unit Hazard Decal Listing 27 28 Pump Hazard Decals 29 Record Of Maintenance Service 30 31 ...

Page 4: ...mpressor 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 supp...

Page 5: ...or restrict operation 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 co...

Page 6: ...d 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 When a compressor pump or component is changed or replaced during the warranty period the newly replaced item is warranted for only the remainder of the original warranty period Repair replacement or refund in the manner and withi...

Page 7: ...SIG COOLING AIR FLOW CFM HEAT REJECTION BTU HR CCE10 3 4 430 3 7 100 450 2100 CCE10 1 575 4 9 100 600 2800 CCE20 1 570 9 6 100 1315 3360 CCE20 2 680 11 5 100 1570 4480 CCE30 3 650 17 1 100 1500 6700 CVE50 5 650 27 4 100 1500 12 000 Minimum Ambient Temperature 32 F Maximum Ambient Temperature 100 F ...

Page 8: ...nk foot It is recommended that unit be set on optional vibro isolator pads Tanks bolted directly to a concrete floor without isolators will not be warranted against cracking 4 If installing a base mounted unit make certain pressure limiting controls are properly installed and operational A pressure switch is required for start stop control Units furnished with dual control are supplied with a pilo...

Page 9: ...SE 1 PHASE MOTOR HP 200 208V 230V 460V 575V 115V 208V 230V 3 4 1 1 2 14 14 14 14 14 14 14 14 10 8 14 10 14 12 2 14 12 14 12 14 14 14 14 8 6 12 8 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 Valves in for duplex unit with one incoming power line to both motors All models require a properly sized magnetic starter as specified in the National Electric Code NEC See Fig...

Page 10: ...N Wiring must be such that when viewing compressor from opposite shaft end rotation of shaft is clockwise as shown by arrow on guard Wrong direction rotation for any length of time will result in damage to compressor 300CHD546 A Ref Drawing 301CHD546 A Ref Drawing ...

Page 11: ...un 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 ...

Page 12: ...motor 3 Activate main disconnect switch 4 Jog motor and check for proper rotation by direction arrow If rotation is wrong reverse input connections on the magnetic starter 5 Close receiver outlet hand valve and start 6 With receiver hand valve closed let machine pump up to operating pressure At this stage the automatic controls will take over Check for proper cycling operation 7 Check for proper o...

Page 13: ...d foreign matter from cylinder cylinder head motor fan blade air lines 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 The V belts must be ...

Page 14: ...ning exceptional care must be taken that all parts are replaced in exactly 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 hand valve at tank outlet for final test COMPRESSOR VALVES CCE20 CCE30 CVE50 Once per year or if compressor fails to pump air or seems slow in filling up tank disconnect unit f...

Page 15: ...arge measure on proper lubrication of the bearings Bearing grease will lose its lubricating ability overtime not suddenly Refer to the motor manufacturer s instructions for the type of grease and lubrication intervals PILOT VALVE Optional Dual Control Units Only The pilot valve actuates the head unloader mechanism to provide a means of stopping or starting the compression of air by the compressor ...

Page 16: ...ease differential pressure 3 After pressure is set tighten locknut 2 Be careful not to move nut 3 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 95 psig reload at 65 psig Turn nut 3 c...

Page 17: ...it and bleed down the air receiver pressure to 0 PSIG 2 Remove the belt guard and the V belt 3 Remove the flywheel 4 Remove the cylinder from the crankcase 5 Loosen the two setscrews in the pin boss area tightened against the pin on the inside area of the piston 6 Push the piston pin out to remove the piston from the top of the con rod 7 Remove crankcase breather cover and foam material on the fro...

Page 18: ...ully remove the crankshaft con rod assembly from the crankcase through the opening in the flywheel end 11 The crankshaft bearings can be removed from the crankcase with bearing puller 12 If the connecting rods need to be removed from the crankshaft jackscrews are provided in the crankcase adjacent to the con rod bearing for this purpose remove the snap ring before using the jackscrews To install a...

Page 19: ... 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 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 valves T...

Page 20: ...lve Warning Relieve tank pressure before servicing 2 Check all wiring Check for loose or faulty wires Check for correct voltage 3 Replace solenoid valve 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 ...

Page 21: ... A61 1 4L510 2 4L510 2 4L510 2 4L510 2 4L510 2 B48 2 6 Belt Guard Z12722 Z12722 Z12722 Z12722 Z9130 Z9130 Z9130 Z9130 Z9130 Z9132 7 Check Valve P05822A P05822A P05822A P05822A P05822A P05822A P05822A P05822A P05822A P05822A 8 Isolation Valve M3590 M3590 M3590 M3590 M3590 M3590 M3590 M3590 M3590 M3590 9 Drain Valve VP1022988 VP1022988 VP1022988 VP1022988 VP1022988 VP1022988 VP1022988 VP1022988 VP10...

Page 22: ...9130 Z9132 3 Base Plate P11933C P11933C P11933C P11933C P11933C P11933C 4 Motor 3 4 HP 1 HP 1 5 HP 2 HP 3 HP 5 HP 5 Pulley 1 PHASE P09947A P09965A P12026A P12027A P11992A P11858C 5 Pulley 3 PHASE P09947A P09949A P12026A P11999A P11992A P11858C 6 Belts A61 1 A61 1 A61 1 4L510 2 4L510 2 B48 2 Note Common to all Units Unloader Solenoid Valve 115V 200V 230V 460V PART NO PART NO PART NO PART NO CC10194...

Page 23: ...A 7 Bucket High Drain Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 8 Pressure Switch P05007A P05007A P05007A P05007A P05007A P05007A P05007A P05007A P05007A P05007A P05007A P05007A 9 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843 10 Motor 3 4 HP 3 4 HP 1 HP 1 HP 1 5 HP 1 5 HP 2 HP 2 HP 3 HP 3 HP 5 HP 5 HP 11 Tank P11936D P11...

Page 24: ...aft Bearing Flywheel End P14346A 1 5 Seal Piston Pin P14345A 2 6 Connecting Rod and Bearing P14351A 1 7 Crankcase Breather P14349A 1 8 Piston Pin P14348A 1 9 Piston P14342A 1 10 Control Ring P14344A 1 11 Compression Ring P14343A 2 12 Piston Ring Set Z12418 1 13 Intake Filter Element P09974A 1 14 Snap Ring 37MM P14355A 1 15 Snap Ring 32MM P14356A 1 16 Cylinder P14357A 1 17 Flywheel P14358A 1 Note F...

Page 25: ...12777A 1 12 Intake Filter Element P05050A 1 P05050A 1 13 Shaft Bearing Front End P12829A 1 P12829A 1 14 Shaft Bearing Flywheel End P12827A 1 P12827A 1 15 Cover Gasket P12825A 1 P12825A 1 16 Connecting Rod and Bearing Z9503 1 Z9503 1 17 Piston Pin P12824A 1 P12826A 1 18 Crankcase Breather P13437A 1 P13437A 1 19 Piston Unloader MT0II CE30 Included on Head Unloader Pumps Only CQP14901A 1 CQP14862A 1 ...

Page 26: ...asket P12776A 2 12 Intake Filter Element P05050A 1 13 Shaft Bearing Front End P12830A 1 14 Shaft Bearing Flywheel End P12828A 1 15 Cover Gasket P12825A 1 16 Connecting Rod and Bearing Z9504 2 17 Piston Pin P12824A 2 18 Crankcase Breather P13437A 1 19 Intercooler Tube P14366A 1 20 Piston Unloader MT0II VE50 Included on Head Unloader Pumps Only CQP14896A 2 21 Cylinder CC1009506 2 22 Pin Crankshaft C...

Page 27: ... Fan Guard 10 NOT USED 11a NOT USED 11b NOT USED 12 NOT USED 13 DECAL Pressure Setting 70 100 PSIG 14 NOTICE Read and Retain Manuals 15 INSTRUCTIONS Dual Control Optional 16 DECAL Rotation Direction 17 NOT USED 18 DECAL Pressure Switch P14677A PUMP HAZARD DECAL LISTING PAGE DESCRIPTION PART NO 29 PUMP DECAL SHEET MASTER P13805A NOT USED A1 NOT USED A2 DECAL Rotation Direction B NOTICE Read and Ret...

Page 28: ...28 UNIT HAZARD DECALS ...

Page 29: ...29 PUMP HAZARD DECALS F ...

Page 30: ...0 RECORD OF MAINTENANCE SERVICE Daily DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS EVERY 3 MONTHS INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 31: ...1 RECORD OF MAINTENANCE SERVICE Daily DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS EVERY 3 MONTHS 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 F3266VER12 F3266VER12 Copyright 2009 Gardner Denver Inc Printed in U S A ...

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