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22 

 

TROUBLE SHOOTING CHART FOR COMPRESSOR 

 
 

 

Always disconnect unit from power supply and relieve all pressure from 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 unit without belt guard in place. 

 

Never use gasoline or flammable solvent on or around compressor unit.  Explosion may 

result.

 

 

 

Troubleshooting Chart

 

Symptom 

Possible Cause(s) 

Corrective Action 

Motor will not start. 
 
 

1. 

Main switch and fuses open. 

 
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 heaters in starter.  Reset 
starter. 

3. 

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

4. 

Repair or replace pressure switch. 

  

Warning – 

Relieve tank pressure 

 

before servicing. 

5. 

Check with voltmeter.  Be sure 

 

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 
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 pressure switch setting. 

2. 

Defective ASME relief valve. 

1. 

Adjust to correct setting. 

2. 

Replace valve.  

  

Warning

 

– Relieve tank pressure 

 

before servicing.  

Excessive belt wear. 

1. 

Pulley out of alignment. 

2. 

Belts too tight or too loose. 

1. 

Realign motor 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 correct rotation. 

 

(Counter clockwise when viewed 

 

from drive side. 

2. 

Install new valve plate assembly. 

3. 

Clean or replace. 

4. 

Clean cylinder fins and/or intercooler. 

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. 

 

Содержание CADRSASP12

Страница 1: ...D 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 TWO STAGE TWO CYLINDER DUPLEX AIR COMPRESSOR UNIT MODEL CADRSASP12 CADRSASP13 Form No CQF3422 VER 01 07 18 2017 ...

Страница 2: ...sor 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 designed with the necessary parts to simplify servicing your compressor Authorized distributor service technicians are factory trained and ski...

Страница 3: ...s 4 Introduction 5 Warranty 5 Dimensions And Specifications 6 Installation 7 thru 16 Operation 16 17 Maintenance Guide 18 Maintenance 19 Maintenance 20 Compressor Oil Specifications 21 Lubricant 21 Torque Values 21 Troubleshooting Chart 22 23 Parts List Unit 24 thru 27 Compressor Repair Parts List 28 thru 34 Receiver Drain Timer 36 Unit Hazard Decal Listing 37 38 Pump Hazard Decals 39 Record Of Ma...

Страница 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...

Страница 5: ...N 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 disclaimed by...

Страница 6: ...it 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 MO...

Страница 7: ...1 5 16 16 1 2 2VB 20 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 R15B 4 5 8 2 1 2 x 3 2 2 109 175 02914 400 990 PERFORMANCE PUMP PRESSURE PSIG MOTOR H P PUMP RPM DISPLACEMENT CFM COOLING AIR FLOW CFM HEAT REJECTION BTU H...

Страница 8: ...t installations require bolting to floor Bolt holes in tank or base feet are provided Before bolting or lagging down shim compressor level Avoid putting a stress on a tank foot by pulling it down to floor This will only result in abnormal vibration and possible cracking of Air Receiver The vibro isolator pads which came with the unit will need to be installed on the unit Tanks bolted directly to a...

Страница 9: ...r property damage 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 NEC All wiring should be performed by a licensed electrician or electrical contractor Wiring must meet applicable...

Страница 10: ...9 FIGURE 1 DUPLEX CONTROL PANEL WIRING DIAGRAM ...

Страница 11: ... disconnect or circuit breaker must be provided by installer LOCK OUT OR TAG OUT ALL SOURCES OF POWER 1 Connect wire for one incoming power line to L1 2 Connect wire for one incoming power line to L2 3 Connect wire for one incoming power line to L3 FIGURE 2 COMPRESSOR POWER CONNECTIONS ...

Страница 12: ...11 INSTALLATION CONT D CIRCUIT BREAKERS 1 Factory wired No wiring required Figure 3 Circuit Breaker ...

Страница 13: ...12 INSTALLATION CONT D MOTOR CONTACTORS 1 Factory wired No wiring required FIGURE 4 MOTOR CONTACTORS ...

Страница 14: ...13 LINE TERMINAL INSTALLATION CONT D PRESSURE SWITCHES SEE FIGURES 4 5 1 Factory wired No wiring required FIGURE 5 PRESSURE SWITCH CONNECTIONS PRESSURE SWITCH FIGURE 4 PRESSURE SWITCH ...

Страница 15: ...14 INSTALLATION CONT D LOW OIL LEVEL MONITOR 1 Factory wired No wiring required FIGURE 6 LOW OIL LEVEL MONITOR ...

Страница 16: ...15 INSTALLATION CONT D ELECTRIC TANK DRAIN 1 Factory wired No wiring required FIGURE 7 ELECTRIC TANK DRAIN ...

Страница 17: ...h both compressors run until receiver pressure reaches the cut out pressure setting of the lead pressure switch To manually set lead compressor set Auto Comp1 Comp2 switch to Comp1 or Comp2 for corresponding compressor to be lead To disable power to a compressor set its corresponding disconnect switch to off set it corresponding TOA switch to off and set the Auto Comp1 Comp2 to the opposite compre...

Страница 18: ... bowl chamber and maintain the same level as in the crankcase The float moves vertically up or down as the oil level changes If the oil level is below minimum allowable operating level the reed switch will open thus stopping the motor A magnet holds the float and prevents the compressor from starting IMPORTANT NOTE The Oil Monitor does not eliminate the compressor owner s responsibility for period...

Страница 19: ...f power supply at wall switch WEEKLY MAINTENANCE 1 Clean dust and foreign matter from cylinder head motor 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...

Страница 20: ...ank 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 th...

Страница 21: ...continues to escape through the release valve it is an indication that the check valve is leaking This can be corrected by removing check valve and cleaning disc and seat If check valve is worn badly replace same 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...

Страница 22: ...ld 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 compres...

Страница 23: ...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 valve plate assembly Tank pressure builds up quickly 1 E...

Страница 24: ... from centrifugal unloader when unit is stopped 1 Check valve stuck in open position 1 Replace check valve Warning Relieve tank pressure before servicing System does not alternate 1 Starter tripped 2 Loose wiring 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 Replac...

Страница 25: ...24 PARTS ILLUSTRATION MODEL CADRSASP12 307CAD810 A Ref Drawing ...

Страница 26: ...witch 2 P14202A 47 Bracket 1 P14418B 13 Compressor 2 Z2412 48 Electric Drain 1 P14240A 14 Screw 8 M3460 49 Strainer 1 P13749A 15 Nut 16 M3483 50 Tube Fitting 2 86A40 16 Filter 2 P04999A 51 Elbow 1 M3088 17 Motor 2 24CA6647 52 Drain Tube 05 FT M2471 18 Screw 8 M3440 53 Tube Insert 2 P10118A 19 V Belt 4 5L680 54 Tubing 5 25 FT P10117A 20 Screw 2 M568 55 Tube Fitting 1 M2862 21 Pulley 2 M7009D 56 Tee...

Страница 27: ...26 DUPLEX CONTROL PANEL MOUNTING 305CAD810 A Ref Drawing ...

Страница 28: ... Screw M3471 4 4 Washer M3481 4 5 Nut M3424 4 6 Screw 75LM97 4 7 Conduit Conn M1883 3 8 Wire M2444 11 0FT 9 Wire M3753 7 0FT 10 Conduit Flex M2461 5 0FT 11 Conduit Conn M1757 3 12 Conduit Conn M1606 1 13 Wire M2438 5 0FT 14 Conduit Extra Flex CC1019312 2 0FT 15 Nut M3485 4 16 Conduit Conn P04131A 1 17 Fitting P13259A 1 ...

Страница 29: ... 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 11A Governor housing gasket 032 Thick SE1430 1 11B Governor housing gasket 005 007 Thick SE1430A 1 11C Governor housing gasket 010 Thick SE1430B 1 11D Gover...

Страница 30: ...igh pressure piston with pin includes items 43 44 ZP02709C 1 43 Piston pin R1021 2 44 Piston pin retaining ring R10102 4 45 Low pressure piston ring set Z798 1 46 High pressure piston ring set Z797 1 47 Cylinder P12237D 1 48 Hex head cap screw M2345 6 49 Low pressure discharge valve assembly Z813 1 50 Valve gasket P04135A 1 51 Discharge valve seat M2097 1 52 Valve disc RE1061 1 53 Valve spring RE1...

Страница 31: ...lve cage P14224B 1 82 Valve spring P13866A 2 83 Valve disc P13865A 1 84 Intake valve seat P14118B 1 85 Gasket Valve HPIN CQP14870A 1 86 Hex head machine screw M3220 1 87 High pressure intake manifold P12302B 1 88 Interstage pressure relief valve M3685 1 89 Intake filter P04999A 1 90 Intake filter element P05050A 1 Complete compressor pump gasket set items 11 14 32 Z764 1 Low pressure piston kit it...

Страница 32: ... 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 C420 B Ref Drawing ...

Страница 33: ...TEM DESCRIPTION PART NO QTY 1 Losc Switch VP1153306 1 2 O Ring 2009222 2 3 Tube Oil CC1153304 1 4 Cap L030 1 5 Conduit Connector M1757 1 6 Conduit CC1019312 1 ft 7 Compression Fitting M2863 1 C508 D Ref Drawing ...

Страница 34: ...S ITEM DESCRIPTION PART NO QTY 1 Auto Comp1 Comp2 Switch P12523A 1 2 Test Off Auto Switch VP1095446 2 3 N O Contact TEN000977 6 4 N C Contact 24CA7111 1 5 Elapsed Time Meter TEN004553 2 6 Circuit Breaker Handle TEN000784 2 ...

Страница 35: ... 24CA6989 2 D Transformer TEN004560 1 E Primary Fuse P10956A 2 F Secondary Fuse TEN004559 1 G Alternator TEN001127 1 H Base Alternator TEN001128 1 I Timer Lag Start TEN004554 1 J Base Timer TEN004555 1 K Line Terminal Ground 24CA5989 1 L Line Terminal 24CA6097 3 M Terminal Block 24CA5984 11 N Ground Terminal Block 24CA5986 2 ...

Страница 36: ...STENER SIZE 1 4 NOTICE The duplex control panel will control two 2 5HP compressors operating at 460V 3phase 60Hz The panel will automatically start and stop the units as well as alternate the starting of units Upstream protection fusible disconnect or circuit breaker must be provided by installer FRONT VIEW SIDE VIEW ...

Страница 37: ...he pressure vessel is depressurized prior to any attempt to install or remove the Drain Timer DO NOT REMOVE the power cord or timer from the valve while the Drain Timer is plugged in If the drain does not seem to be working properly contact your distributor Any attempt to repair the drain without authorization will VOID WARRANTY 1 Fully drain the vessel by opening an auxiliary gate valve or push t...

Страница 38: ... 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 39 PUMP DECAL SHEET MASTER P13805A NOT USED A1 NOTICE Lubricants A2 DECAL Rotation Di...

Страница 39: ...38 UNIT HAZARD DECALS ...

Страница 40: ...39 PUMP HAZARD DECALS F ...

Страница 41: ...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 ...

Страница 42: ...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 ...

Страница 43: ...2 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 ...

Страница 44: ... CQF3332VER01 CQF3332VER01 For additional information contact your local representative or visit www championpneumatic com 2016 Champion Inc Printed in U S A ...

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