Champion BDR5K Operation Maintenance Manual & Parts List Download

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OPERATION/MAINTENANCE

MANUAL & PARTS LIST

Diesel Engine Driven Two Stage Air

Compressor Featuring the R15BHU Compressor

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.

MODELS

HDR5–3K
HDR5–3Y
HDR5-8K
HDR5-8Y
BDR5K
BDR5Y

Form No. CQF3355 VER: 02 12/22/2014

Summary of Contents for BDR5K

Page 1: ... 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 MODELS HDR5 3K HDR5 3Y HDR5 8K HDR5 8Y BDR5K BDR5Y Form No CQF3355 VER 02 12 22 2014 ...

Page 2: ......

Page 3: ...h these services 1 Trained parts specialists to assist you in selecting the correct replacement parts 2 A full line of factory tested CHAMPLUB compressor lubricants specifically formulated for use in Champion compressors 3 Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor Authorized distributor service technicians are factory trained and skilled in...

Page 4: ... Introduction 5 Warranty 5 Dimensions And Specifications 6 Installation 7 Operation 8 9 Maintenance 10 thru 12 Compressor Pilot Valve Differential Pressure Adjustment 12 Compressor Oil Specifications 13 Lubricant 13 Torque Valves 13 Trouble Shooting Guide 14 Unit Repair Parts List 15 thru 24 Compressor Repair Parts List 25 thru 29 Unit Hazard Decals 30 Pump Hazard Decals 31 Maintenance Kits 32 Rec...

Page 5: ...exposed openings with clean cloth or Kraft paper 11 Do not operate the compressor without guards shields and screens in place 12 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 shut off valve 13 Do not operate compressor in areas where there is a possibility of ingesting flammabl...

Page 6: ...N THE PARTS LIST SECTION 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 ai...

Page 7: ...ufactured 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 MOTORS G...

Page 8: ...Bolt Hole to Wheel Max Flywheel Width Crank Diameter Flywheel Diameter Flywheel Grooves Overall Depth 10 4 3 8 5 8 5 1 2 18 23 1 4 15 32 7 1 2 5 3 4 7 8 3 5 8 2 1 2 1 5 16 16 1 2 2VB 20 NOTE Flywheel Rotation Clockwise when viewed from front flywheel to rear SPECIFICATIONS MODEL BORE STROKE INCH NO of CYLINDERS OIL CAPACITY QTS WEIGHT LBS MAXIMUM PRESSURE PSIG CU FT REV MIN MAX RPM R15BHU 4 5 8 2 ...

Page 9: ...loor without isolators will not be warranted against cracking Champion vibro isolators or approved equivalent must be installed for extended warranty to apply to ASME receivers 4 If installing base mounted unit make certain the pressure limiting controls are properly installed and operational The unloading system requires a control air pressure line from the air receiver to be connected to the pil...

Page 10: ...s AIR LINE PIPING Connection to air system should be of the same size or larger than discharge pipe out of unit The table gives recommended minimum pipe sizes A union connection to the unit is recommended Install a flexible connector between the discharge of the unit and the air piping Piping should be periodically inspected for leaks using a soap and water solution for detection on all pipe joint...

Page 11: ...ring installation 2 Check compressor oil level Add oil as required See Compressor Oil Specifications Section NOTE Do not mix oil type weights or brands 3 Check engine oil level Add oil as required Consult engine manual for oil specifications 4 Close receiver outlet valve 5 Flip toggle lever on pilot valve to the Manual Unload position See Figure 1 Figure 1 6 Start engine Allow engine to warm up 7 ...

Page 12: ... exceeds 25 PSIG WEEKLY MAINTENANCE 1 Clean dust and foreign matter from cylinder head engine fan blade air lines intercooler and tank 2 Remove and clean intake air filters Do not exceed 15 PSIG nozzle pressure when cleaning element parts with compressed air Do not direct compressed air against human skin Serious injury could result Never wash elements in fuel oil gasoline or flammable solvent 3 C...

Page 13: ...inal test Valve gaskets should be replaced each time valves are removed from pump CENTRIFUGAL UNLOADER AND PRESSURE RELEASE VALVE The centrifugal unloader is operated by two governor weights It is totally enclosed and lubricated from the crankcase of the compressor When compressor starts the governor weights automatically open compressing the main spring allowing the unloader pressure release valv...

Page 14: ...unloader mechanism to provide a means of stopping or starting the compression of air by the compressor without stopping or starting the electric motor DIESEL ENGINE For service refer to separate engine manual COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running 1 Loosen locknut 4 and back off several turns Do not turn differential pressure ...

Page 15: ...f the oil level 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 lub...

Page 16: ... 3 Lack of air to pilot valve 1 Adjust to correct sitting 2 Replace pilot valve 3 Check piping from tank to pilot valve for leaks Excessive belt wear 1 Pulley out of alignment 2 Belts too tight or too loose 1 Realign engine pulley 2 Adjust belt tension Compressor runs hot 1 Improper flywheel rotation 2 Defective compressor valves 3 Dirty air filter 4 Dirty cylinder and or intercooler 1 Check for c...

Page 17: ... 2 Mounting Plate 300CAE4017 1 3 Screw M3460 3 4 Nut M3483 2 5 Motor Mounting Bracket 300CAE145 2 6 Eye Bolt VP1096404 1 7 Screw 655ED09AZ 1 8 Elbow M980B 1 9 Nipple P08798A 2 10 Ball Valve VP1022988 1 11 Cross 64K1 1 12 Pressure Relief Valve M2843 1 13 Pressure Gauge M519C 1 14 Elbow 86A40 1 15 Ball Valve M3590 1 331CAE810 A Ref Drawing ...

Page 18: ... 2 Mounting Plate 300CAE4017 1 3 Screw M3460 3 4 Nut M3483 2 5 Motor Mounting Bracket 300CAE145 2 6 Eye Bolt VP1096404 1 7 Screw 655ED09AZ 1 8 Elbow M980B 1 9 Nipple P08798A 2 10 Ball Valve VP1022988 1 11 Cross 64K1 2 12 Pressure Relief Valve M2843 1 13 Pressure Gauge M519C 1 14 Elbow 86A40 1 15 Ball Valve M3590 1 333CAE810 A Ref Drawing ...

Page 19: ... BDR5Y BASE PLATE GROUP Ref No Description Part Number Qty 1 Base plate 300CAE285 1 2 Mounting Plate 300CAE4017 1 3 Screw M3460 3 4 Nut M3483 2 5 Motor Mounting Bracket 300CAE145 2 6 Eye Bolt VP1096404 1 7 Screw 655ED09AZ 1 313CAE810 A Ref Drawing ...

Page 20: ...PAIR PARTS ILLUSTRATION MODELS HDR5 3K HDR5 3Y HDR5 8K HDR5 8Y BDR5K BDR5Y Compressor Group Ref No Description Part Number Qty 1 R15BHU Compressor CC1119843 1 2 Screw M3460 4 3 Nut M3483 4 307CAE810 B Ref Drawing ...

Page 21: ... PARTS ILLUSTRATION MODELS HDR5 3K HDR5 3Y DISCHARGE GROUP Ref No Description Part Number Qty 4 Tube Fitting M2867 1 5 Discharge Tube 303CAE857 1 6 Tube Fitting M2350 1 7 Check Valve P05822A 1 317CAE810 A Ref Drawing ...

Page 22: ...UNIT REPAIR PARTS ILLUSTRATION MODELS HDR5 8K HDR5 8Y DISCHARGE GROUP Ref No Description Part Number Qty 4 Tube Fitting M2867 2 5 Discharge Tube 302CAE857 1 8 Check Valve P05822A 1 326CAE810 A Ref Drawing ...

Page 23: ...ne VP1136277 1 2 Oil Drain VP1099934 1 3 Throttle Control Bracket CC1134655 1 4 Throttle Control Valve VP1135897 1 5 Nut 50W5 1 6 Nut M3483 1 7 Bushing P09799A 1 8 Pulley P13197A 1 9 Belt 13E544 10 Belt Guard 304CAE120 4 11 Bracket M855 1 12 Nut M3485 1 13 Bracket CC1023978 2 14 Bracket M856 1 15 Screw M1454 1 319CAE810 C Ref Drawing ...

Page 24: ...ol Bracket 303CAE017 1 4 Throttle Control VP1097563 1 5 Tube Fitting 86E229 1 6 Washer 121097Z 1 7 Lock Washer 95B13Z 1 8 Screw VP1096937 1 10 Nut M3483 4 11 Bushing P09799A 1 12 Pulley P13197A 1 13 Belt 13E544 2 14 Belt Guard 304CAE120 1 15 Bracket M855 1 16 Nut M3485 3 17 Belt CC1023978 1 18 Bracket M856 1 19 Screw M1454 2 29 Bracket 304CAE017 1 31 Screw 75LM47 2 318CAE810 B Ref Drawing ...

Page 25: ...y 9 Tube Fitting M2863 1 10 Elbow M3251 1 20 Tube Insert P10118A 6 21 Tubing P10117A 1 9ft 22 Tubing P10117A 75ft 23 Tubing P10117A 1 01ft 24 Tube Fitting M2868 1 25 Delay Valve P09263A 1 26 Nipple M3174 2 27 Tee M3474 1 28 Pilot Valve VP1089041 1 32 Screw M3465 1 33 Tube Fitting M2862 1 322CAE810 A Ref Drawing ...

Page 26: ...umber Qty 9 Tube Fitting M2863 1 20 Tube Insert P10118A 6 21 Tubing P10117A 1 47ft 22 Tubing P10117A 1 10ft 23 Tubing P10117A 79ft 24 Tube Fitting M2868 1 25 Delay Valve P09263A 1 26 Nipple M3174 2 27 Tee M3474 1 28 Pilot Valve VP1089041 1 32 Screw M3465 1 33 Tube Fitting 86A40 1 321CAE810 A Ref Drawing ...

Page 27: ...71 98 99 60 82 81 80 79 78 77 76 75 74 73 72 68 67 66 65 64 63 62 56 55 54 53 52 51 50 49 59 58 57 60 59 69 84 83 70 60 58 39 36 37 40 43 44 46 44 45 43 44 41 40 36 37 34 13 14 15 11 16 17 18 17 19 20 21 22 23 26 25 24 31 30 29 28 27 11A 11B 11C 11D 61 C392 B Ref Drawing COMPRESSOR REPAIR PARTS ILLUSTRATION Model R15BHU ...

Page 28: ...17 Governor weight SE582B 2 18 Governor weight pin SE592A 2 19 Lock washer M3468 1 20 Hex head cap screw M2345 1 21 Flat washer M912A 1 22 Governor spring SE590 1 23 Spring sleeve SE587 1 24 Governor housing cover RE10100A 1 25 Unloader muffler assembly Z4593 1 26 Head machine screw M3473 6 27 Release valve assembly Z12414A 1 28 Release valve plunger SE586B 1 29 Release valve ball P07841A 1 30 Rel...

Page 29: ... 62 Valve gasket P04137A 1 63 Discharge valve seat RE757A 1 64 Valve disc RE1062 1 65 Valve spring RE760 1 66 Discharge valve cage M2100 1 67 Gasket Valve CQP14869A 1 68 Hex head machine screw M3220 1 69 High pressure discharge manifold M1717 1 70 Pressure relief valve P09704A 1 71 Low pressure intake valve unloader assembly Z4877 1 72 Gasket Valve CQP14832A 1 73 Intake valve cage M2098 1 74 Valve...

Page 30: ...6A 1 96 High pressure intake manifold P12304B 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 1 Low pressure piston kit items 41 45 Z9101 1 High pressure piston kit items 42 46 Z9100 1 Complete compressor pump ring set items 45 46 Z799 1 Complete valve set w gaskets Z6795 1 Complete ...

Page 31: ...y 1 Compression fitting M2868 1 2 Tube Unloading w Fittings ZSB250A 1 3 Compression Fitting M2864 2 4 Breather Tube w Fittings ZUB375 1 5 Compression Fitting M2879 2 6 Manifold Tube Z9172 1 7 Intercooler w Fittings Z9140 1 8 Compression Fitting M2868 1 9 Compression Nut VP1061773 1 305CAP810 B Ref Drawing ...

Page 32: ...30 UNIT HAZARD DECALS ...

Page 33: ...DESCRIPTION PART NO PUMP DECAL SHEET MASTER P13805A NOT USED 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 PUMP HAZARD DECALS ...

Page 34: ...32 MAINTENANCE KITS DESCRIPTION Qty Part Number R10 R15 Compressor Maintenance Kit includes the following Z11882 Air Filter Element 1 P05050A Oil 1 Quart 2 P13796A ...

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

Page 36: ... CQF3355VER02 CQF3355VER02 For additional information contact your local representative or visit www championpneumatic com contactus aspx 2014 Gardner Denver Inc Printed in U S A ...

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