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Champion A Series, Operating And Service Manual

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Champion A Series Operating And Service Manual Download Page 16

C1--1--608

Page 9

STANDARD DIMENSIONS & RUNNING CLEARANCES

UNIT COLD -- NEW COMPONENTS

Inches

mm

CYLINDER BORE

7.875/7.876

200.025/200.050

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PISTON -- RING LAND DIAMETER

7.839/7.835

199.111/199.009

. . . . . . . . . . . . . . .

PISTON TO CYLINDER -- AT RING LAND

.036/.041

.9144/1.0414

. . . . . . . .

PISTON -- SKIRT DIAMETER

7.8650/7.8640

199.771/199.746

. . . . . . . . . . . . . . . . . . . .

PISTON TO CYLINDER -- AT SKIRT

.0100/.0120

.254/.305

. . . . . . . . . . . . . .

RING GAP -- COMPRESSION

.010/.020

.254/.508

. . . . . . . . . . . . . . . . . . .

RING SIDE CLEARANCE -- COMPRESSION

.0020/.0045

.051/.114

. . . . . .

RING GAP -- OIL

.010/.050

.254/1.270

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING SIDE CLEARANCE -- OIL

.002/.008

.051/.203

. . . . . . . . . . . . . . . . . .

PISTON -- PIN BUSHING BORE

1.0095/1.0100

25.641/25.654

. . . . . . . . . . . . . . . . .

PISTON PIN DIAMETER

1.0082/1.0080

25.608/25.603

. . . . . . . . . . . . . . . . . . . . . . . .

PISTON PIN TO BUSHING

.0013/.0020

.033/.051

. . . . . . . . . . . . . . . . . . . . . .

CONNECTING ROD -- CRANKPIN INSERT BORE

2.750/2.749

69.850/69.825

.

CRANKSHAFT -- CRANKPIN DIAMETER

2.6230/2.6225

66.624/66.612

. . . . . . . . .

INSERT THICKNESS

.06250/.06225

1.588/1.581

. . . . . . . . . . . . . . . . . . . . . . . . . . .

INSERT TO CRANKPIN

.001/.003

.0254/.0762

. . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING RODS SIDE CLEARANCE ON

CRANKPIN

.010/.025

.254/.635

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT DIAMETER -- AT MAIN BEARING

2.5015/2.5025

63.538/63.564

. .

MAIN BEARING I.D.

2.5000/2.5005

63.500/63.513

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN BEARING HOUSING BORE

CRANKCASE

4.4355/4.4365

112.662/112.687

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEARING HOUSING

4.4355/4.4365

112.662/112.687

. . . . . . . . . . . . . . . . . . . . .

MAIN BEARING O.D.

4.4375/4.4385

112.713/112.738

. . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING ROD PISTON PIN BORE

1.010/1.008

25.654/25.603

. . . . . . . . .

MAIN BEARING END CLEARANCE

0 TO .001

0/.254

. . . . . . . . . . . . . .

Summary of Contents for A Series

Page 1: ...CHAMPIONR A SERIES COMPRESSOR VACUUM PUMP MODELS 3 STROKE APLGAA APLGBA APLHAA APLHBA 4 1 2 STROKE APOGAA APOGBA APOHAA APOHBA PARTS LIST OPERATING AND SERVICE MANUAL C1 1 608 1st Edition July 1999 ...

Page 2: ...orsepower L 15 HP Compressor Vacuum O 30 HP Compressor Vacuum Column 4 Construction G Single Stage with Suction Unloading Valves H Single Stage with Plain Valves Column 5 Rotation A Counterclockwise Rotation B Clockwise Rotation Column 6 Design Version A P A __ __ __ __ __ __ 1 2 3 4 5 6 ...

Page 3: ...ned with the necessary parts to simplify servicing your compressor Authorized distributor service technicians are factory trained and skilled in compressor mainte nance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your local authorized Air Compressor dealer refer to the local yellow pages of your phone directory or...

Page 4: ...ng Repair Parts i Index iii Foreword iv Safety Precautions v Installation and Operating Instructions 1 Trouble Shooting 8 Standard Dimensions Running Clearances 9 Torque Values 10 Crankcase Group 11 12 Cylinder Group 13 Valve Group 14 Single Stage Compressor Vacuum Pump 15 16 Piston Ring Arrangement 17 Breather Plug Assembly 17 Unloader Piping 18 Decals 19 Spare Parts Repair Kits 20 21 Warranty La...

Page 5: ...ocation 1 Lubricating System 4 Lubrication 3 Main Bearings 7 Maintenance 4 Maintenance Daily 4 O Rings and Gaskets 7 Oil Change 5 Parts List Breather Plug Assembly 17 Crankcase Group 11 12 Cylinder Group 13 Decals 19 Piston Ring Arrangement 17 Single Stage Compressor Vacuum Pump 15 16 Spare Parts Repair Kits 20 21 Unloader Piping 18 Valve Group 14 Piping 1 Piston Pin Bushings 7 Piston Pins 7 Pisto...

Page 6: ...ult in economical operation and mini mum downtime Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severeperson al injury death or substantial property damage if the warning is ignored Caution is used to indicate the presence...

Page 7: ...and the air pressure has been relieved D Electrical shock will result in injury or death to personnel Open main discon nect switch before working on the control D Compressor unit must be grounded in accordance with the National Electrical Code D Disconnect the compressor unit from its power source tag and lockout before working on the unit this machine is automatically controlled and may start at ...

Page 8: ...relocating the filters from the unit to aremote location PIPING Air discharge pipe must be the full size of the discharge opening on the air cylinder The discharge pipe should be as short and direct as possible eliminat ing short bends and fittings and avoiding pockets A Pressure Relief Valve must be placed in the discharge line between the compressor and any shutoff valve check valve or aftercool...

Page 9: ...t only protect against personal in jury or death but to also protect the equipment from damage from foreign objects STORAGE After completing test of the compressor a protective type oil to retard rust and corrosion is FIGURE 2 ROTATION AS VIEWED FROM SHEAVE END CLOCKWISE COUNTER CLOCKWISE sprayed into the suction intake to protect interior of heads valves and upper cylinder section This is done wi...

Page 10: ...e first 40 hours COLD WEATHER STARTING In addition to the nor mal starting procedure make sure the weight of the oil in the crankcase is suitable for existing temperatures Refer to Lubrication section below Start the unit un der no load and stop before gaining full speed Repeat this operation until pressure registers on the oil gauge or until oil has a chance to reach all moving parts After the un...

Page 11: ...on back side of cover engage in recessed area of pump as shown CCLW Shaft Rotation of Oil Pump with Cover Removed CLW Shaft Rotation of Oil Pump with Cover Removed APL Comp VAC Pump Oil Pump End NOTE Suction Port of Pump Shaded cleaning solvents and wiping rags are necessary to avoid transferring dirt into the unit Clean the exterior of the unit before starting work to prevent dirt from enter ing ...

Page 12: ...down the compressor check the oil level and add if necessary When starting the unit after an oil change start under no load until assured that oil has reached all moving parts Condensate accumulation in the crankcase will often occur as a result of high humidity conditions wide tem perature range and intermittent service CRANKCASE BREATHER The crankcase breather should be washed each time the oil ...

Page 13: ...ether must go up away from the piston Refer to parts list for assembly views SUCTION VALVE UNLOADING MECHANISM Un loading the compressor is accomplished by a plunger holding all suction valves off their seats when the pre determined air pressure for which the unloading con trol is set is reached When air is applied above the plunger piston the entire assembly moves as a unit un til the valve is fo...

Page 14: ... on the insert must fit in the corresponding re cess in the rod and cap Do not file ends of inserts or rod caps Assemble the rod and cap with cast timing marks on the same side Tighten bolts evenly until proper torque is attained Do not torque each bolt to rating sep arately as this will cause the rod bore to deform to an out of round condi tion CRANKSHAFT OIL SEAL The crankshaft oil seal must be ...

Page 15: ...ntrol pressure switch diaphragm ruptured 10 O ring on suction unloader plunger leaking NOISY VALVES 1 Loose assembly 2 Unloader spring broken 3 Broken valve spring s 4 Weak valve spring s 5 Badly worn parts SHORT VALVE LIFE 1 Dirt entering unit 2 Heavy carbon deposits 3 Corrosive vapors entering unit 4 Uneven or worn valve seat 5 Weak or collapsed valve spring s 6 Compressor over speed 7 Very rapi...

Page 16: ...0100 25 641 25 654 PISTON PIN DIAMETER 1 0082 1 0080 25 608 25 603 PISTON PIN TO BUSHING 0013 0020 033 051 CONNECTING ROD CRANKPIN INSERT BORE 2 750 2 749 69 850 69 825 CRANKSHAFT CRANKPIN DIAMETER 2 6230 2 6225 66 624 66 612 INSERT THICKNESS 06250 06225 1 588 1 581 INSERT TO CRANKPIN 001 003 0254 0762 CONNECTING RODS SIDE CLEARANCE ON CRANKPIN 010 025 254 635 CRANKSHAFT DIAMETER AT MAIN BEARING 2...

Page 17: ...pection Plate To Crankcase Screws 5 16 18 13 15 17 20 Shroud Plate Screws 3 8 16 23 25 31 35 Cylinder To Crankcase 1 2 13 55 60 74 81 Sheave Nut 1 1 4 12 500 550 678 746 Cylinder Head To Cylinder 1 2 13 55 60 74 81 Valve Center Screw 1 2 13 55 60 74 81 Valve Center Screw 5 16 18 13 15 17 20 Connecting Rod Crankpin Screws 1 2 13 55 60 74 81 Connecting Rod Piston Pin Screw 3 8 16 23 25 31 35 ...

Page 18: ...C1 1 608 Page 11 CRANKCASE GROUP 200ASL810 K Ref Drawing ...

Page 19: ...USING 0075 3 202ASL732 24 SHIM BEARING HOUSING 005 3 203ASL732 25 FILTER ADAPTOR ASSEMBLY 1 201ASL070 26 PIN GROOVED 1 62V35 28 PLUG SQHD 2 64AC2 29 ELBOW PIPE 1 64X7 30 OIL PUMP KIT Includes 31 32 and 33 1 200ASL188 31 PUMP OIL 1 2010242 32 BUSHING TRANSFER 1 2010244 33 SPRING 1 2010245 34 SHIM BEARING HOUSING 020 1 204ASL732 35 ADAPTOR FILTER OIL 1 200ESF070 36 FILTER OIL 1 26C28 37 SHIM SET 1 2...

Page 20: ...O RING 1 25BC433 56 SCREW 6 655EE060 85 VALVE 7 7 8 1 See page 14 86 PLUNGER UNLOADER Used with Suction Valve Only 1 203ASL184 86 PLUG Used with Plain Valve Only 1 64AA5 87 O RING Used with Suction Valve Only 1 25BC118 121 PISTON AIR 1 204ASL015 122 BEARING SLEEVE BRONZE 2 12BA135 123 PIN PISTON 1 62F63 3 Stroke 4 1 2 Stroke CONNECTING ROD KIT Includes next four items 2 201ASL6001 202ASL6001 111 C...

Page 21: ...VE ASSEMBLY Includes Ref No 71 83 212ASL529 210ASL529 71 SEAT DISCHARGE VALVE 1 202WLA203 202WLA203 72 SEAT SUCTION VALVE 1 200WLA202 200WLA202 73 SPRING VALVE 17 202ASL105 202ASL105 74 VALVE DISC 1 90V57 90V57 75 VALVE DISC 1 90V56 90V56 76 VALVE DISC 1 90V54 90V54 77 O RING 1 25BC205 25BC205 78 O RING 1 25BC110 25BC110 79 SCREW 1 655EE090 655EE060 80 SPACER 1 201VEG144 NONE 81 SPRING 1 78A174 NO...

Page 22: ...C1 1 608 Page 15 SINGLE STAGE COMPRESSOR VACUUM PUMP 226ASL810 F Ref Drawing ...

Page 23: ... 168 SHROUD FAN 1 202ASL647 169 SCREW FLANGED HEAD 6 75LM51 170 NUT FLANGED 6 50AW5 171 WASHER 1 95A11C 172 LOCKNUT 1 50V9 173 MANIFOLD SUCTION 1 204ASL069 174 GASKET 2 25C1801N 175 SCREW 2 655EE180 176 SCREW 6 655EE050 177 MANIFOLD DISCHARGE 1 202ASL071 178 GASKET 2 206WLA715 179 SCREW 8 655EE050 181 NIPPLE 1 202ASL126 182 REDUCER 1 64N25 183 DIPSTICK 1 201ASL491 184 O RING 1 25AM18 185 BREATHER ...

Page 24: ... only PISTON RING ARRANGEMENT 256ASL810 A Ref Drawing BREATHER PLUG ASSEMBLY 200ATS191A Ref Drawing 65AA20 65AA4 65AA20 65AM280 Ref No Name of Part Qty Part No BREATHER PLUG ASSEMBLY Includes next four items 200ASL034 1 BREATHER PLUG 1 200ASL191 2 BALL 1 10A6 3 PIN 1 62V17 4 EXPANSION PLUG 1 66A1 ...

Page 25: ...art Number and Description Reference Numbers are for your convenience only 208ASL810 Ref Drawing UNLOADER PIPING Ref No Name of Part Qty Part No 221 TEE TUBE 1 86E119 222 ELBOW TUBE 1 86E60 223 TUBE 1 216ASL857 224 CLAMP 2 98A27 ...

Page 26: ...ce only 239ASL810 Ref Drawing DECALS Ref No Name of Part Qty Part No 211 DECAL DANGER 1 206EAQ077 212 DECAL DANGER 3 212EAQ077 213 DECAL WARNING 2 200ASL077 214 DECAL CAUTION 1 201ASL077 215 TAG INSPECTION 1 200ATS304 216 DECAL QUALITY 1 251EAQ077 217 NAMEPLATE 1 201ASL496 219 DECAL ARROW 3 69F6 ...

Page 27: ... 8 PLAIN VALVE 1 210ASL529 SUCTION UNLOADING VALVE REBUILD KIT 7 7 8 209ASL6017 Includes next thirteen items O RING 1 25BC422 O RING 1 25BC433 SPRING VALVE ASSEMBLY 17 202ASL105 DISC VALVE 1 90V57 DISC VALVE 1 90V56 DISC VALVE 1 90V54 O RING 1 25BC205 O RING 1 25BC110 SPRING 1 78A174 FINGER UNLOADER 1 202ASL183 WASHER 1 95F5 O RING 1 25BC118 O RING 1 25BC100 PLAIN VALVE REBUILD KIT 7 7 8 205ASL601...

Page 28: ... four items 201ASL6001 ROD CONNECTING 1 203ASL003 SCREW 2 75LM195 SCREW 1 655ED080 BEARING 2 200ADL174 CONNECTING ROD KIT 4 1 2 STROKE Includes next four items 202ASL6001 ROD CONNECTING 1 201ASL003 SCREW 2 75LM195 SCREW 1 655ED080 BEARING 2 200ADL174 PISTON RING KIT 7 7 8 COMPRESSION OR VACUUM 202ASL6012 Includes next three items PISTON RING ASSEMBLY 1 65AM280 PISTON RING ASSEMBLY 2 65AA20 PISTON ...

Page 29: ...roved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedules caused by but not limited to location or inaccessibility of the equipment or labor provided by unauthorized service personnel is not provided by this warranty All costs of transportation of product or parts claimed not to be as warrant...

Page 30: ...presentative or Princeton Customer Service Department 1301 N Euclid Ave Princeton Illinois 61356 Telephone 815 875 3321 FAX 815 872 0421 Sales and Service in all major cities For parts information contact Master Distribution Center Memphis TN Telephone 800 245 4946 FAX 901 542 6159 http www championpneumatic com mktg gardnerdenver com ...

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