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OPERATION/MAINTENANCE
MANUAL & PARTS LIST
TWO STAGE/RV LINE AIR COMPRESSORS & UNITS
MODELS RV15A & RV30A
AWARNING
THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND MUST
BE
AVAILABLE TO THOSE PERSONNEL OPERATING THIS EQUIPMENT.
READ, UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT
TO PREVENT INJURY OR EQUIPMENT DAMAGE.
PNEUMATIC MACHINERY CO., INC.
MODEL RV.15A COMPRESSOR PUMP SHOWN
.
.
COMPLETE NATION-WIDE ORGANIZATION OF
OiAMPION REPRESENTATIVES AT YOUR SERVlæ
AN EQUAL OFPORTIJNITY EMPLOYI)R
.
Princeton, lllinois 61356-9990. Phone (815) 875-3321 FAX (815) 872-0421
Manufacturing Plants in Princeton, lllinois Manteca, California
1301
N. Euclid Ave.
Form No. 102894 Rev. 695
Table of Contents
Subject
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Safety Precautions
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Introduction
Warranty
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Page
5
5
3&4
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10
11
10&11
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12 & 13
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23
22
14 thru 21
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9
7 & 8
6 & 8
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~&
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<'
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and Operation
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Dimensions and Specifications RV 15A
.
.
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Dimensions and Specifications RV30A
Installation
.
.
Preparation for Initial Start-Up
Maintenance
Oil Specifications
.
Troubleshooting Guide
Parts List
.-.
Hazard Decal and Tag Listing
.
......
Maintenance Schedule Fill-In Chart
FOR PARTS: REFER TO PARTS DEPOT LIST
ACCOMPANYING THIS MANUAL.
2
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SAFETY AND OPERATION PRECAUTIONS
Alwayswear safety glasses when usingcompressed air gun.
-
-
(NEC)and
Do not operate the compressor WIThout guards, shields and screens in
place.
Do not install a shut-off valve in the dischargeline, unless a
pressure relief valve, of proper design and size,
is installed in the line between the
unIT
shut-off
compressor
and
valve.
Do not operate compressor in areas where there is a possibilITyof ingesting
flammable or toxic fumes.
Be careful when touchingthe exterior of a recentlyrun motor it
may be hot enoughto be painfulor cause
injury. WITh modern motors this condITion is normal if operated at rated load
modern motors are built to
operate at highertemperatures.
InspectunIT çlaily to observe and correct any unsafe operatingconditions found.
Do not "playaround" with compressed air
because this can cause injuries.
Compressedair from this machine absolutelymust not be used for food processingor breathingair without
adequatedownstream filters, purifiersand controls.
Always use an air pressure regulatingdevice at the point of
use.
Check hoses for weak or worn condition before each
use and make certain that all connections are secure.
Do not attempt to remove any compressor parts without first relievingthe entire system of
pressure.
Do not attempt to service any part while machine is in an operationalmode.
Do not operate the compressor at pressures in
excess of its rating.
Do not operate compressor at speeds in
of its
rating.
excess
Periodicallycheck all safetydevices for proper operation. Do not change
pressure settingor restrict operation
in any way.
Be sure no tools, or rags or loose parts are left on the
compressor or drive parts.
Do not use flammable solvents for cleaningthe air inlet fitter
element
and
other
parts.
or
Exercise cleanliness duringmaintenance and when making repairs. Keepdirt away from parts
by covering
parts and exposed openingswith clean cloth or Kraft paper.
Make certain that the power source conforms to the requirementsof your equipment.
Pull 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. "Tag out"
or "lock out" all power sources.
Electric motors must be securely and adequatelygrounded. This
can be accomplished by wiring WITh a
grounded, metal-clad raceway system, by usinga separate groundwire connected to the bare metal of the
motor frame, or other sUITable
means.
Protect the power cable from coming in contact WITh sharp objects. Do not kink
power cable and never allow
the cable to come in contact WITh oil, grease, hot surfaces, or chemicals.
For installation,follow all local electrical and safetycodes, as well as the National Electrical Code
the OccupationalSafetyand Health Act (OSHA).
Read all instructions completelybefore operatingair compressor or unit.
Because an air compressor is a piece of machinery with movingand rotatingparts, the
same precautionsshould be
observed as WITh any piece of machineryof this type where carelessness in operation maintenance is hazardous
or
to personnel. In addITion to the many obvious safety rules that should be followed WITh this
type of machinery, the
addITional safetyprecautionsas listed below must be observed:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
prevent all injuriesor equipmentdamage.
The user of any air compressor package manufactured by ChampionPneumatic
MachineryCompany,
is hereby
Inc.,
warned that failure to follow the preceding Safety and Operation Precautions can result in injuries
or equipment
damage. However, ChampionPneumatic Machinery
Company,
Inc., does not state as fact or does not mean to imply
that the precedinglist of Safety and OperatingPrecautions is
all inclusive, and further that the observance of this list
will
3
Indicates immediate hazards which will result in severe injury or death.
EXPLANATION OF SAFETY INSTRUCTION SYMBOLS AND DECALS
ADANGER
result in severe
Indicates hazards or unsafe practice which could
injury or death.
in
Indicates hazards or unsafe practice which could result
damage to the Champion compressor or minor injury.
~WARNINGI
IACAUTIDN
I
AS
OBSERVE, UNDERSTAND AND RETAIN THE INFORMATION GIVEN IN THE SAFETY PRECAUTION DECALS
SHOWN IN THE PARTS UST SECTION.
AOANGER
air
This reciprocatingcompressor must not be used for breathing air. To do so will cause serious injury whether
for
is supplied direct from the compressor source or to breathing tanks for later use. Any and all liabilities
damage or loss due to injuries, 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.
\AWARNING
I
atmospheric air is strictly
The use of this compressor as a booster pump and/or to compress a medium other than
void the warranty.
non-approved and can result in equipment damage and/or injury. Non-approved uses will also
IACAUTIDN
I
This unit may be equippedwith special options which may not be included in this manual. User must read,
understand and retain all information sent with special options.
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Introduction
Your new ChampionReciprocatingAir Compressor is constructed to exacting standards of material and
workmanship.
The instructions in this manual have been prepared to ensure that The CHAMPION
will give long and
satisfactoryservice.
requestsfor information,service, spare parts or Maintenance Manual replacementshould include machine
A copy of this manual must be givento the personnelresponsiblefor installingand operatingThe CHAMPION
air compressor or untt.
Althoughprecautionshave been taken to prevent damage to your compressor or unit by freightcarrier, the
unit must be carefully examined and the carrier notified wtthin 24 hours in the event of mishandling.
All
serial number and be directed to:
CHAMPION PNEUMATIC MACHINERY CO., INC.
Service Department
1301 N. Euclid Avenue
(815)875-3321
(815)872-0421
Princeton, Illinois 61356 USA
Phone:
Fax:
EXPRESS LIMITED WARRANTY
CHAMPION.warrants each new piece of equipmentmanufactured by CHAMPION to
free from defects in material and
be
workmanshipunder normal use and service of a period of twenty-four (24) months from date of installation
or thirty (30)
months from date of shipmentby 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
warranted only to the extent of the original
are
manufacturer's warranty to CHAMPION. To have warranty consideration, electric
motors must be equippedwith thermal
overload protection.
When a compressor pump, or component is changed
or replaced duringthe warranty period, the newly replaced item is
warranted for only the remainder of the originalwarranty period.
Repair, replacement or refund in the manner and within the time providedshall constitute CHAMPION'S
sole liability and
your exclusive remedy resultingfrom any nonconformity defect. CHAMPION SHALL NOT IN ANY
or
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 WITH RESPECT TO THE EQUIPMENT OR ITS FAILURE TO OPERATE
EVEN IF CHAMPION HAS BEEN
ADVISED OF THE POSSIBILITY THEREOF.
CHAMPION MAKES NO WARRANTY OR REPRESENTATION OF ANY
KIND, EXCEPT THAT OF TITLE, AND ALL
OTHER WARRANTIES,EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE,ARE HEREBY EXPRESSLY DISCLAIMED. NO
SALESMANOR OTHER REPRESENTATIVE
OF CHAMPION HAS AUTHORITY TO MAKE ANY WARRANTIES.
5
*
Motor
HP
3
*5
71/2
F
DIMENSIONS
Q
I-
RV15A
B
A
Bo~ Down-Width
Base-Width
16-112
iTEM
C
Bo~ Down to Edge
CTR
Base to Crank
24-112
10
D
Overall Width
Bo~ Down Depth
FlywheelWidth
124
WT. LBS.
175 PSIG
5/8
5-112
22
15/32
5-3/4
7-112
7/8
3
2-112
1-5/16
17-112
2VB
16-112
MAX. PRESS
NOTE: H.P. ExhaustOpening3/4" Tubing
FlywheelGrooves
Depth
4-3/8
F
Base to
E
G
I
Base-Depth
Overall Height
Top
MODELS RV.15A
TWO STAGE AIR COMPRESSORS.
G
J
K
Bo~ Down to Edge
Bo~ Hole to Wheel (Max.)
Bo~ Down Hole Dia.
L
M
N
OILCAPY.
Crank Diameter
Flywheel Diameter
CU.FT.lREV.
20T.
Overall
NO. CYLS.
.02914
R
BORE & STROKE
2
0
P
Q
4-5/8 & 2-1/2 X 3
PUMP SPECIFICATIONS
Rotation of Flywheel: Clockwise when viewed
from front end, flywheelto rear.
PUMP
RV-15A
Motor Pulley
OD.lnches
PERFORMANCE DATA FOR RV-15A COMPRESSOR
BTU/Hr
Heat Rejection
Cooling Air Flow
CFM
RPM
4.35
Pump
6700
7.35
1035
775
Displ
22.6
CFM
530
12,000
9.75
Press
PSIG
460
895
16,800
13.4
175
30.2
MIN RPM 400
MAX RPM 1050
1195
175
-
175
noted.
1800 RPM electric motors as a power source, unless
00 motor pulley.
1 Ph, 3450 RPM motor uses 3.75"
All data is based on
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BORE & STROKE
DIMENSIONS
p
0
~
N
RV-30A
Base-Width
7
ITEM
A
Bo~ Down to Edge
25
9-3/4
17/32
24-7/8
3/4 NPT
4-13/16
3/4
11-1/8
B
C
Base to Crank Ctr
Height
Bo~ Down-Width
D
Overall
HP Exhaust at Opening
Bo~ Down Hole Dia.
E
F
Base-Depth
G
I
H
8-1/16
27/32
Crank Diameter
18-7/8
2-23/32
1-3/4
3-1/4
FlywheelDiameter
21-1/2
2VB
Flywheel Grooves
Overall Depth
Bolt Hole to Wheel (Max.)
Flywheel Width
Edge
Bo~ Down Depth
Bo~ Down to
L
J
K
M
N
0
P
WT. LBS.
175 PSIG
MAX. PRESS.
R
-
Flywheel Rotation;Clockwise When
FlywheelTo Rear
OILCAPY.
233
Viewed From Front
CU. FTJREV.
40T.
BTU/HR
REJECTION
HEAT
CFM
6.2
COOLING
AIR FLOW
16,800
8.15
11.35
a power source.
22,400
33,600
-
-
-
2VB
2VB
2VB
MOTOR
PULLEY
OD.INCHES
.0583
PUMP SPECIFICATIONS
NO. CYLS.
4
Overall Width
MODEL RV-30A COMPRESSOR PUMP
(2) x 3
PUMP
2Y2
4 5/8
(2) &
RV30A
RPM
PUMP
PERFORMANCE DATA FOR RV.30A COMPRESSOR
CFM
DISPL.
740
575
840
1080
1515
1800 RPM electric motors as
1040
33.52
PSIG
175
60.62
43.13
PRESS.
175
MOTOR
HP
10
175
7Y2
15
All data is based on
Min. RPM 400
Max. RPM 1050
-
x
Flvwheel Dia.
Motor or EngineRPM
(approx.) Pump RPM
TO DETERMINE PULLEY SIZE: Select a
compressor which will deliver the requiredCFM at the desired pressure. Note
the speed (RPM) compressor must
run at to meet above requirements and the flywheel diameter of compressor.
Determine RPM, shaft and keyway size of motor
or engine. To determine pulley diameter, use this formula:
Pulley Dia.
7
MOTOR HP
5
7-%
-
208V
8
230V
-
SPECIFICATIONS
-
SINGLE PHASE
8
ELECTRIC WIRING (BASEDON 1993 NEC)
300C Ambient
CopperConductor 750C Temp. Rating
Wire Size (RubberCovered) AWG NO.
120V
-
460V
14
6
230V
14
14
-
200/208V
12
14
14
-
10
10
12
10
THREE PHASE
MOTOR HP
8
8
10
575V
5
8
6
7-%
10
4
%
1
%
50
,
1
%
75
1
%
100
1
%
150
1%
1
200
11f.l
1
250
11f.l
1
300
LENGTH OF PIPE LINE IN FEET
PIPE SIZES FOR COMPRESSED AIR LINES
(Basedon Clean, Smooth Schedule 40 Pipe)
15
25
RV15A
%
PUMP MODEL
RV30A
pipingmaterials can burst and cause injury or
\AWARNING
I
Improper
Never use plastic pipe or improperly rated metal pipe.
property damage.
8
f})\
fan
bladed
flywheel, which
so close to
the
through
cools
Do not install in an area where ambient
temperature is below 32 degrees F or
above 100 degrees F.
IACAUTION
I
at the point of use. Failure to do so can result
in injury or equipment damage.
Always use an air pressure regulating device
IAWARNING
I
cause excessive pressure if valve is closed
and cause injury and equipment damage.
Do not install
isolating valves
between
compressor outlet and air receiver. This
will
ADANGER
or a Mark
If installing a bare pump, make certain the system
has adequatepressure limitingcontrols. Controls
could be a pressure switch for start/stopoperation
II pilot valve for continuous
operation.
warranted against cracking.
As an alternative, install unit on optional vibroisolator pads.
Tanks bolted directly to a
concrete floor without padding will not be
or base feet are provided. Before bolting or
laggingdown, 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 possiblecrackingof Air Receiver.
tank
Place stationarycompressors on firm level ground
or flooring. Permanent installations seldom
require bolting to floor, however, bolt holes in
wall.
compressor, is impeded. Permanently mounted
units should have flywheel at least 12" from
the
a wall or other obstruction that flow of air
Compressorsshould never be located
warranty.
or paint, found to have clogged the air intake
filters and intake valves, shall automatically void
a compressor, used for painting, be located in a
separate room from that area wherein body
sandingand paintingis done. Abrasive particles
Permanently installed compressors must be
located in a clean, well ventilated dry room
so
compressor receives adequate supplyof fresh,
clean, cool and dry air. It is recommended that
INSTALLATION
1.
2.
3.
4.
.
.
.
Do not install unit in an area
where air
is dirty and/or chemical laden.
Unit is not to be installed
outdoors.
9
ELECTRICAL POWER SUPPLY
It is essential that the power supplyand the supply
wiringare adequatelysized and that the voltagecorrespond
All
or electrical
wiring should be performed by a licensed
contractor.
Wiring must meet
to the unit specifications.
electrician
applicablecodes for area of installation.
Recommended electrical wiring specifications
are
listed in
.Specifications.
section.
If ordered with a mounted starter, compressor unit
on compressor, and attach to terminals as
is pre-wired at factory. It is necessary only to bringlines
from properly sized disconnect switch to magnetic starter
mounted
indicated
schematic diagram located inside cover of
on
control.
Be sure that power circuit and voltage
correspond with the specifications.
!ACAUTION
I
Wiring must be such that when viewing
compressor from oppositeshaft end, rotation
of shaft is clockwise as shown by arrow on
guard. Wrongdirection rotation for any length
of time will result in damage to compressor.
AIR LINE PIPING
drop leg is
Connection to air system should be
of
the same
size, or larger,
discharge
of
out
unit. See
than
pipe
recommended pipingsizes in "Specifications"
section. A
to the unit and water
Install a flexible connector between the
union connection
recommended.
dischargeof the unit and the plant air piping. Plant air
pipingshould be periodicallyinspectedfor leaks usinga
soap and water solution for detection on all pipejoints. Air
leaks waste energy and are expensive.
Activate main disconnect switch.
installation.
would
Inspectunit for any visible signsof damage that
have occurred in shipment or during
Do not attempt to operate compressor on
voltage other than that specified on order
or on compressor motor.
Check compressor oil level. Add oil as required.
See section on "Oil Specifications".
IAWARNING
I
Pull main disconnect switch to unit to
assure that
no power is cominginto the unit "Tagout" switch.
Connect power leads to starter.
PREPARATION FOR INITIAL START-UP
AND OPERATION
1.
2.
3.
4.
5.
"Jog" motor and check for proper rotation
by
direction arrow. If rotation is wrong, reverse input
connections on the magneticstarter.
Open receiver hand valve. The air compressor
unit is now ready for use.
oil level.
Check for proper operation of any options, e.g.
LOSC. Refer to individual optioninstruction sheet.
When the initial run period has shown no
operating problems,shut unit down and recheck
proper cyclingoperation.
pump up to operating pressure. At this stage the
Check for
automatic controls will take over.
Close receiver outlet hand valve and start unit.
With receiver hand valve closed, let machine
PREPARATION FOR INITIAL START.UP (CONT'D)
6.
7.
8.
9.
10.
GUIDE TO MAINTENANCE
consistent
keepingthe
To obtain reliable and satisfactoryservice, this unit requires
A
preventive maintenance schedule.
a
proper records.
maintenance schedule form is included to aid in
!AWARNING
I
Before performing any maintenance function,
switch main disconnect switch to "off"
position to assure no power is entering unit.
Lock out or tag out all sources of power. Be
sure an air pressure in unit is relieved. Failure
to do this may result in injury or equipment
damage.
Turn off compressor at the end of each
operation. Turn off power supplyat wall switch.
day's
Drain moisture from tank by opening tank drain
drain
cock located in bottom of tank. Do not open
valve if tank pressure exceeds 25 PSIG.
if so equipped. Add
required. See Section on
Check oil level of both compressor and engine
quality lubricating oil as
.Oil Specifications..
DAILY MAINTENANCE
1.
2.
3.
Remove and clean intake air filters.
tank.
Clean dust and foreign matter from cylinder
head, motor, fan blade, air lines, intercooler and
WEEKLY MAINTENANCE
1.
2.
!AWARNING
I
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
in fuel oil, gasoline or flammable
solvent.
elements
10
3.
1.
Check V.belts for tightness. The V-belts must
power
be tight enoughto transmit the necessary
to the compressor. Adjustthe V-belts as follows:
mountinghardware which secures motor
within slots of baseplate to
Slide
Remove bolts and guard to access compressor
drive.
Loosen
motor
to base.
desired position.
bottom
Adjust if
of adjacentbelt. Make further adjustments
Applypressure with fingerto one belt at midpoint
is correct if top of belt aligns with
span. Tension
if necessary.
Check the alignment of pulleys.
necessary.
base.
guardand secure
with bolts.
Tighten mounting hardware to secure motor on
Re-install
\AWARNING
I
Never operate unit without belt guard in place.
rotating parts which can
Removal will expose
cause injury or equipment damage.
oil
Pull ring on all pressure relief valves to assure
proper operation.
Valve plates must be replaced In original
positions. Valve plate gaskets should be
replaced each time valves are serviced.
!ACAUTIDN!
Tighten nuts and capscrews as required.
Check and clean compressor valve plates as
required. Replace worn or damagedparts.
solution and brush.
Check entire system for air leakage around
fittings, connections, and gaskets, using soap
.
Change crankcase oil. Use type and grade
Oil
as specifiedin the section on .Compressor
Specifications.
EVERY 90 DAYS OR 500 HOURS
MAINTENANCE
2.
3.
4.
5.
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service refer to separate manual
GENERAL MAINTENANCE NOTES
ELECTRIC MOTOR: For
maximum pressure permitted
by
or chart attached to equipment.
PRESSURE RELIEF VALVE: The pressure relief valve is
an automatic pop valve. Each valve is properly
adjustedfor the
tank specifications and 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 in
order to reseat properly. Do not readjust.
TANK
Drain valve is located at bottom of
DRAIN
VALVE:.
tank.
Open drain valve daily to drain
a week.
The pressure switch is automatic
condensation. Do not open drain valve if tank
pressure exceeds 25 PSIG. The automatic tank
drain equipped compressor requires draining
manually once
PRESSURE SWITCH:
and will start compressor at the low pressure and
stop when the maximum pressure is reached. It
is adjustedto start and stop
compressor at the
proper pressure for the unit on which it is installed.
Do not readjust.
BELTS: Drive belts must be kepttight enoughto prevent
If belts slip or squeak,
slipping.
see V-belt
maintenance in precedingsection.
/ACAUTION
I
If bellS are too tight, overload will
be put
on motor and motor bearings.
COMPRESSOR VALVES: If compressor fails to
pump air
or seems slow in filling up tank, disconnect unit
from power source and remove valve platesand
clean thoroughly,using compressed air. After
cleaningexceptionalcare must
taken that all
be
parts are replaced in exactly the
same position
and all jointsmust be tight or the compressor will
not function properly.
When all valves are
replaced and connections tight, close receiver
outlet valve for final test. Valve plate gaskets
stops operating, preventingair from
The check valve closes when the
should be replaced each time valve
sets are
removed from pump.
CHECK VALVE:
compressor
flowing
of
tank
out
through
the
the pressure
release valve.
After the
compressor stops
operating, if air continues to
escape throughthe
unloader
release
it
is
valve,
indication that the
an
check valve is leaking. This
can be corrected by
removingcheck valve and cleaningdisc and
seat.
If check valve is worn badly, replace
same.
11
THE
RELIEF
VALVE
is
!AWARNINGI
PRESSURE
valve
Before removing
check
be
sure all
air
in unit is
and power
released
pressure
is disconnected. Failure to do
so may
result in injury or equipment damage.
INTERSTAGE
provided to protect against interstage over
pressure and is factory set for maximum pressure
of 75 PSIG.
Inspect
DO NOT RESET
If the pressure relief valve
it indicates
pops,
Shut down the unit immediately
and
trouble.
determine and correct the malfunction.
the head valves. Serious
damage
can result if not
completedestruction of
corrected and can lead to
proper level as indicated byoil sightgauge.
crankcase filled as requiredby usage.
Keep
the unit. Tamperingwith the interstagepressure
relief valve, or plugging
the openingdestroysthe
protectionprovided and voids all warranty.
LUBRICATION OF COMPRESSOR:
Fill crankcase to
1.
ELECTRIC MOTORS
be made.
2. For the first 100 hours of compressor operation,
a careful and regularcheck of the oil level should
Maintain oil level at the full line.
1. Do not mix oil types, weights, or brands.
Consult factoryfor the use of syntheticlubricants.
NOTES:
oils can be obtained from the service department.
distributor for information and purChase of this oil.
For temperatures below 32 degreesF, use
an ISO
68 compressor oil. A separate list of acceptable
maintained usingthe ISO 100 recipoil for ambient
temperatures above 32 degrees F. This is a 30
weight, non-detergentindustrial oil with
rust
and
oxidation inhibitors specially
formulated
for
reciprocating compressors.
Contact your
It is recommended that this compressor be
have any oil in the crankcase. Be sure to add oil
to these pumps prior to start-up.
Compressorsshippedas basic (pumponly)do not
with
AIR COMPRESSOR
Compressorsshipped on units are factory filled
ISO 100 recip oil.
COMPRESSOR OIL SPECIFICATIONS
2.
Electric motors are equippedwith sealed-for-Iife
bearingsand requireno additionallubrication.
C
B
A
Excessive Belt Wear
Compressor Won't Shut Off
Compressor Pumps Too Slowly
Compressor Runs Hot
6
5
4
3
2
1
Pipe Line Leaks
Compressor Pump Valves
Improper FlywheelRotation
ImproperNV" Belts Tension
Excess Water in Air Receiver
Diaphragmin Pressure Switch
Points in Pressure Switch
........
:;:;:::::;:;::::
F
E
D
:.:.:.:.:.:.:.:.:.:.
:.:.:.:.:.:.:.:.:.:.
;:::::::::::;:::
;:::::::::::::::
E
D
:.:.:.:.:.:.:.:.:.:.
.:.:.:.:.:.:.:.:.:.:
::::::::::::::::
::::::::::::::::
::::::::::::::::
:.:.:.:.:.:.:.:.
::::;:::::;:;:::
:::::::::;::::::
:;:;:;:;:;:;::::
.:.:.:.:.:.:.:.;
::::::::::::;:;:
G
C
................
.:.:.:.:.:.:.:.:
B
;:::;:::;:::::::
A
2
3
4
6
7
8
9
11
10
:;:;:;:;:;:;:;:;
5
~~~~t;;t;~
::::::::::::::;:
;:;:;:;:;:::;:;:
.:.;.;.;.;.;.;.:
tt~~~jt
::::::::::::::::
:;:;:::;:;:;:;:;
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B
A
12
~~t;~;tm
:::;:::;:;:;:;::
:::::::::;::::::
~;~:~:~:~:~:~:~:
;:;:;:;:::::::;:
C
1
Never use gasoline or flammable solvent on or around compressor unit.
Explosionmay result.
Never operate compressor without belt guardin place.
damageor injury.
switches. Failure to do so may result in equipment
Always disconnect unit from power supplyand relieve all pressure from air
all electric
tank before performing any maintenance. "Lock Ouf or "Tag Ouf
TROUBLE SHOOTING CHART FOR COMPRESSOR
IAWARNING
I
0
Abnormal Pressure Fluctuation
SERVICE PROBLEM
E
7
Check Valve is Leaking
F
Air Escapes From Pressure Switch Unloader Muffler When Stopped
InterstageSafetyRelief Valve Pops Off Continuously
8
Check Valve or Line to Tank is Plugged
H
F
G
9
Belts Misaligned
G
Compressor Cycles(runs)too Often
10
Dirty Intake Filter
H
H
11
Crankcase Oil Level Too Low
POSSIBLE CAUSE OF PROBLEM
12
FOR EXPLANATION SEE NEXT PAGE
12
ff,~0,
~jJI!}
t)))
)
/..1
,
f
.
1./2.
3.
4.
5.
6.
7.
8.
9.
EXPLANAllON OF TROUBLE SHOOllNG CHART
A pressure switch uses a diaphragm to open and close a set of points. Points may become pitted or
"touching" up with sandpaper or replace. See instructions in pressure
use. Clean by
dirty through
switch.
Disconnect unit from power source before checking pressure
IAWARNINGI
switch cover.
a
week.
Water in the form of vapor is compressed along with incoming air and condenses in tank. Tank must
be drained daily so that full storage capacity of tank may be used. To drain, open pet cock on bottom
of horizontal or vertical tank. If compressor is equipped with automatic tank drain, drain manually once
Do not open drain valve if tank pressure exceeds 25 PSIG.
IAWARNINGI
"V" belts must be tight enough to transmit the necessary power to the compressor; if too tight they will
overload the engine or motor. If, by pushing down on one belt, its top lines up with the bottom of the
belt next to it, the tension is correct. Should it be necessary to change the tension, slide the engine
or motor in slots provided in tank baseplate to desired position.
in
the direction shown by the arrows.
Disconnect unit from power source before working on belts.
Always reinstall belt guard after adjusting belts.
IAWARNINGI
The fan blade flywheel must rotate
Compressor valves may become fouled by carbon or other foreign matter. To service, remove head
and extract valve plates. Clean all valve plates. Reinstall, taking caution that all parts are returned to
their original position.
Replace
All air lines from compressor to tank and from tank to air operated devices should be tight. A soap
solution will show bubbles when put on a leaky joint. At 175 PSIG a 1/32" hole will allow almost 3 cubic
feet per minute of air to escape.
Before servicing check valve, be sure pressure in tank is ZERO and power is disconnected.
check valve.
Badly worn compressor which is pumping oil may deposit carbon within discharge tube and check valve,
restricting flow of air and possibly plugging these parts completely. These parts should be cleaned or
replaced.
Disconnect unit from power source and relieve tank pressure
before servicing these components.
IAWARNING!
Motor pulley and flywheel must be in line to prevent wear on sides of belts. If misaligned, move pulley
by loosening set screw on key and tapping pulley in appropriate direction.
in or out
Intake filter should be cleaned periodically to allow unrestricted flow of entering air. To service filter,
disassemble filter and remove elements. Element may be blown clean with air nozzle if moderately
dusty. Heavily fouled elements should be replaced. Never clean elements with fuel oil, gasoline or
flammable solvent.
10.
11.
Cool running and long life can be assured by careful attention to crankcase oil. Check frequently and
change as indicated on compressor data sheet.
Disconnect unit from power source before adjusting pulley.
~WARNINGI
12.
13
6
PARTS LIST
MAJOR COMPRESSOR COMPONENTS
SHOWN]
~:[NOT
10
PUMP
5 HP
MOTOR
ELEC.
2
M7009D*
M7009D*
PULLEY
MOTOR
3
P01164D
P01596D
P01164D
AIR
TANK
4
B69
B69
5L680
5L680
V-BELT
5
Z5447
Z7189
Z7189
Z307
Z307
GUARD
BELT
6
P07538A
P07538A
P07538A
P07538A
P07538A
VALVE
CHECK
7
M2686
M2686
M2686
M2685
M2685
HAND
VALVE
8
P05875A
P05875A
P05875A
P05875A
P05875A
SWITCH
10
11
RV15A
5 HP
P07981A
P01596D
B81
P05875A
7
~"._.(I
HRV5-8
RV15A
7% HP
P07981A
P01400D
M2686
MODEL HRV5-12 SHOWN
HRV5-12
RV15A
7% HP
M2920
P07538A
1
HRVlF-8
RV15A
10 HP
Z5447
-
-
Pulley
P08136A Bushing
use: P07784A
PRESS
HRVlF-12
RV30A
B81
MODEL
NUMBER
HRV10-8
P01596D
-
M2920
5HP 1 Phase Units with 3450 RPM Motor
10 HP
*
RV30A
M519C
M2843
M521
HRV10-12
DRAIN COCK
PRESSURE GAUGE
PRESSURE RELIEF VALVE
PARTS COMMON TO ALL MODELS:
(9)
(11)
(12)
14
~>>~
0)'
\
./
J:
o
f))
RV.15A
PARTS LIST
.,
1
M1820
1
~2
FLYWHEEL & CRANKCASE
"
1
M2326
Pipe Plug
Pipe Plug, Oil
1
,
2
M459
1
REa.
3
M492
Pipe Nipple, Oil Drain
Cap, Oil Drain
1
NAME
4
M461
Gauge, Oil Level
1
PART NO.
5
RE714
Flywheel
1
ITEM
6
NR7A
Key, Flywheel
1
13
12
11
SE1430B
SE1430A
1
1
1
1
1
1
7
U8
Screw, Hex Head
Crankcase
8
M738
Nut, Hex
1
Fill
9
M465
GASKET
1
14
10
Z130
Gasket, Gov. Housing(.030" Thick)
Gasket, Gov. Housing(.005" Thick)
1
SE1430C
NRSOA
SET,Gov. Housing
SE1430
Housing,Governor
Gasket, Gov. Housing(.010. Thick)
Gasket, Gov. Housing(.015" Thick)
15
16
4
P07358C
SE1489
NR104
Screw, Hex Head
Compression Fitting
Cover, Governor Housing
1
8
1
1
19
M2400
GASKET SET, COMPLETE PUMP
M472
Plate, Baffle
Screw, Hex Head
Gasket, Governor Cover
20
M2864
17
18
21
ZSOO
1
22
15
7
ITEM
2
OSN4
R155
ZNR16
6
11
9
@}-13
6
REa,
11
10
9
ITEM
Z797
ZM2090
R1021
R10102
ZM2091
4
5
1
12
1
3
2
1
1
REa,
Piston, low Pressure wlPin
Piston, HighPressure wlPin
NAME
Pin, Piston
1
4
KIT, L.P. Piston Þssy.
(Includesitems 9,11,12&14)
1
1
1
1
KIT, RING. SET
(Includesitems 13 & 14)
-
(Includesitems 10 13)
Ring, Piston Pin Retaining
RING SET, H.P. Piston
RING SET, L.P. Piston
KIT, H.P. Piston Þssy.
ø
PARTS LIST
RV.15A
CRANKSHAFT, PISTON AND CONNECTING ROD ASSEMBLY
Þ
1
2
13
7
Crankshaft
Main Bearing Þssy.
2
2
Z798
PART NO.
Seal, Oil
ConneciingRod Þssy. (Items 5-8)
14
NAME
Connecting Rod
4
Not Sold Separately
Z799
Z796
Z795
Dipper, Oil
Bearing, Piston Pin
BoI~ Connecting Rod
=
2
2
l~'
3
PART NO.
4
Z750
NSS
M1583
R1524
1
7
R1037
5
8
NOTE: NSS
16
,;
,,'I
)'ì'"
~',;)/;,
tJ))"
;".,\\\,
4.1
w
t)
10
6
RV-15A
PARTS LIST
PART NO.
~
I
I
NAME
@
CYLINDER, VALVE AND HEAD ASSEMBLY
7
2
ITEM
NAIE
REa.
PART NO.
13
ITEM
1
ZP04472C
SE541
REa.
1
Gasket, Cylinder Range
14
3
NR29A
1
Tube, Intercooler
1
Cylinder
3
M2087
Nut, Compression
2
Ferrule, Compression
22
P03592A
P05050A
Filter, Intake
1
1
1
Element, Filter
Interstage Pressure Relief Valve
1
9
SE542
M2598
Screw, Hex Head
Gasket, Upper Cylinder
15
M2597
16
P04421C
1
3
6
4
1
2
5
14
Screw, Hex Head
Nut, Locking
Valve, Pressure Relief
Plate, Valve
P08295A
Valve, Reed
17
M2088
19
23
P04999A
18
P07497A
28
20
21
1
Screw, Reed Valve
2
1
1
M1565
Stud, Valve Plate
1
Fitting, Compression
P05611 A
Gasket, Valve Plate
1
10
P09704A
M2869
6
7
P04420C
Plate, Valve
1
Tube, Breather
M2089
Head
Gasket, Head
ZM2150
P04419C
8
9
M2086
11
12
17
ITEM
1
2
PART NO.
PARTS LIST
1~
13~11
14/
16
)
I
I
I
./
J
RV-30A
CRANKCASE & FLYWHEEL
27
-"'--6
.
~
1
1
1
6
NR367B
M461
RE714
M459
M460
Cap, Oil Drain
Gauge, Oil level
Flywheel
1
1
1
26
25
23
24
M?864
M1795
4
7
Key, Flywheel
1
27
5
,
NAME
1
"'~4
PART NO.
Housing,Governor
Gasket, Gov. Housing(.015" Thick)
4
17
ITEM
P10095C
SE3030C
Screw, Hex Head Cap
1
20
15
M2345
SE3089
Gasket, Gov, HousingCover
Plate, Baffle
8
u
16
NR361 04
1
REa.
1
SE301 00
Cover, Governor Housing
Screw, Hex Head
1
RE208
1
22
8
M738
Screw
Nut, Hex Head
1
REa.
1
17
M2400
Pipe Plug
1
9
M465
GASKET SET, Gov. Housing
Gasket, Gov. Housing(.030" Thick)
1
NAME
Pipe Plug
Crankcase
1
18
M1796
Body,Release Valve
10
Z3030
SE3030
Gasket, Gov. Housing(.005" Thick)
Gasket, Gov. Housing(.010" Thick)
1
11
SE3030A
M1898
M2326
1
19
SE30101
Gasket, Release Valve Body
12
SE3030B
1
1
1
1
1
20
M1507
1
13
3
Pipe Plug, Oil Fill
Pipe Nipple,Oil Drain
1
21
SE585
Cap, Release Valve
Pipe Plug
CompressionFitting
14
18
l~-)
'1ì~
f)
12
13
14~
11
4
5
7
12
KIT, RING SET
(Includesitems 13 & 14)
Pin, Piston
Ring, Piston Pin Retaining
RING SET, L.P. Piston
RING SET, H.P. Piston
KIT, H.P. Piston Assy.
(Includes items 10,11,12 & 14)
KIT, L.P. Piston Assy.
(Includesitems 9,11,12 & 13)
NAME
1
~
PARTS LIST
RV-30A CRANKSHAFT, PISTONS & CONNECTING ROD ASSY.
9
"-
R1021
2
11
R10102
PART NO.
1
12
ITEM
PART NO.
Crankshaft
2
REa.
ITEM
P10094B
Main BearingAssy.
NAME
1
ZNR2016
2
4
Z799
Z796
Z795
Z798
8)
13
-
1
OSN36A
ConnectingRod Assy. (Items5
Seal, Oil
3
ConnectingRod
Z797
Z752
14
NSS
4
5
4
4
8
4
Dipper, Oil
2
Bol~ConnectingRod
Bearing, Piston Pin
2
R1024
Piston, Low Pressure w/Pin
M1583
RE1037
Piston, HighPressure wlPin
7
8
ZM2091
ZM2090
6
9
10
NOTE: NSS = Not Sold Seperately
19
3
REO,
8
4
2
2
2
2
2
ITEM
NR29A
M2087
PART NO.
2
M2597
1
3
11
12
,
,
t'18
~
I
@
I
CiiJ
1,;-
21
T
'",;~
2
19
4
10
9
Head
4
6
PARlS LIST
RV-30A CYLINDER, VALVE AND HEAD ASSEIIBL Y
7
4
ITEM
M2086
Nut, Compression
18
1
12
SE541
Ferrule, Compression
2
REa.
13
SE542
M2598
REa.
2
14
4
NAME
NAME
2
15
1
PART NO.
Gasket, Cylinder Flange
2
12
P08295A
Fitting, Compression
Screw, Hex Head
Nut, Locking
Valve, Pressure Relief
1
16
P09704A
Cylinder
4
P04421C
M2088
M2869
Screw, Cap, Hex Head
Gasket, UpperCylinder
5
17
18
2
28
P07497A
1
Plate, Valve
Valve, Reed
M1565
1
Screw, Reed Valve
7
6
Tube, Breather
56
4
ZM2153
Stud, Valve Plate
19
P05611 A
1
8
Filter, Intake
2
2
Element,Filter
Gasket, Valve Plate
P04999A
P05050f'
Plate Valve
20
21
P04420C
Gasket, Head
9
M2089
2
P04419C
10
11
20
~f)i
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-
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~~.
PARTS LIST
RV-30A TUBING, ETC.
M2326
InterstagePressure Relief Valve
Plug, Pipe
2
1
2
2
REO.
10
9
8
7
ITEM
ZP04474D
ZM2154
ZP04473D
M480
8
P03592A
Tube, Aftercooler, Left
2
PART NO.
ZM2155
Nut, Compression
NAME
SE-5-41
2
PART NO.
3
SE-5-42
Ferrule, Compression
ITEM
4
Fitting, Compression
2
1
5
M2867
6
21
3
6
4~ 5
1
1
REO.
Tee, Pipe
NAME
Tube, Aftercooler, Right
1
1
Tube, Intercooler, Right
Tube, Intercooler, Left
1
3
all
TAG
-
-
-
-
-
4
AIR FROM THIS COMPRESSOR
MUST NOT BE USED FOR FOOD
PROCESSING OR BREATHING
WITHOUT ADEQUATE FILTERING.
P.SSS6A
OnEN IN DUSTY
CONDITIONS
M173a
CAUTION, SERVICE FILTER
ELEMENTS WEEKLY
MORE
DESCRIPTION
RETAIN LABELS
DANGER, ADEQUATE FILTERING
ROTATION DIRECTION
SERVICE FILTER
DANGER, VALVE INSTRUCTIONS
DECAL
DECAL
DECAL
DECAL
PUMP HAZARD DECAL LISTING
NOTICE
Read"
understand,& retain
P09819A
labelS and OwnersManuals
before usingthis equipment.
ROTATION IN DIRECTION OF ARROW
M442
5
P09879A
P08586A
M442
M1736
P09852A
PART NO.
MOIlIlV::IO NOIl~31lIa NI NOI.l.VlOIl
ITEM
1
2
3
4
5
22
A.~'l.'"
~)1 Jl
Ay
"-I,.
~j,
0)
0)
to
.
DRAIN MOISTURE FROM TANK
CHECK OIL LEVEL
DAILY
.
CLEAN FILTER.
CLEAN COMPRESSOR
CHECK V-BELTS
WEEKLY
.
.
.
.
.
...
INSPECT AIR SYSTEM
MONTHLY
RECORD OF MAINTENANCE SERVICE
23
TEST PRESSURE RELIEF VALVE
CHANGE OIL
INSPECT VALVE ASSEMBLIES
TIGHTEN ALL FASTENERS
EVERY 3 MONTHS
.
.
.
.
.
.
CHECK OIL LEVEL
DRAIN MOISTURE FROM TANK
DAILY
.
.
.
CLEAN COMPRESSOR
CHECK V-BELTS
CLEAN FILTER
WEEKLY
.
.
-
RECORD OF MAINTENANCE SERVICE
INSPECT AIR SYSTEM
MONTHLY
.
TEST PRESSURE RELIEF VALVE
CHANGE OIL
INSPECT VALVE ASSEMBLIES
TIGHTEN ALL FASTENERS
EVERY 3 MONTHS
.
.
.
.
-"
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.
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