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Champion HR3-6, Operation & Maintenance Manual

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Champion HR3-6 Operation & Maintenance Manual Download Page 22

22

CONSTANT SPEED HEAD UNLOADER KIT Z9144

For Air Compressor Pump Models R-10D

 

and R-15B

NOTE:  This is optional equipment and may not be included on your unit. 

The purpose of constant speed unloading is to provide a means of stopping or starting the compression of air by the compressor
without stopping or starting the electric motor or gasoline engine after each cycle.

To accomplish this, an air pilot valve is used to replace the pressure switch used for stop-start operation.  The pilot  valve  senses
 storage  tank pressure, and when the pressure is raised to a predetermined setting, this air is released to an intake valve hold-open
mechanism. The compressor stops compressing air and runs free until the pilot valve senses that the pressure in the tank has
dropped to the predetermined setting.  At this time the air is released from the intake valve hold-open mechanism, and the
compressor starts compressing air again.

The parts called out below replace or are substituted for those found in the regular parts list.

Z9144 - CAPTURED UNLOADER VALVE

R-10D, R-15B

REF. NO.

TOTAL

REQ'D

PART NO.

LOW PRESSURE

-

1
2
3
4
5

6
7
8
9

1
1
1
1
1
1

1
1
1
1

Z6312

P09670C
P02306B
P09923A
P02547A

Z4877

P09085A
P09084A
P09086A
P09083A

LP Intake Manifold Group (includes 1,2,3,4)
LP Intake Manifold
Cylinder
Unloader Piston
O-Ring
LP Valve Assembly
(includes 6,7,8,9)
Unloader Finger
Unloader Spring
Locknut
Guide Stem

REF. NO.

TOTAL

REQ

PART NO.

HIGH PRESSURE

 Z9143 HP

-

1
2
3
4
5

6
7
8
9

10
11

1

1
1
1
1
1

1
1
1
1
1
1

Z9143

P12304B
P02306B
P09923A
P02547A

Z6308

P09297A
P01882A
P09086A
P09296A
P00746A
P09171A

HP Intake Manifold Goup
(Includes items 1,2,3,4,10)

HP Intake Manifold
Cylinder
Unloader Piston
O-Ring
HP Valve Assembly
(includes 6,7,8,9)
Unloader Finger
Unloader Spring
Locknut
Guide System
Cylinder Gasket
Valve Gasket
(not included)

REF.

NO.

TOTAL

REQ'D

PART NO.

HIGH & LOW PRESSURE

12
13
14
15
16
17
18
19
20

1
1
1
1
1
1
1
1
1

M2879

Z9172

M2868

P12323A

M2853
M2881
M3465

M807

M2868

Compression Fitting
Manifold Tube
Compression Fitting
Actuating Tube
Pilot Valve
Compression Fitting
Screw, Hex Head Cap
Mounting bracket
Compression Fitting

TYPICAL MINIFOLD ASSEMBLY

FOR HEAD UNLOADERS

Summary of Contents for HR3-6

Page 1: ...RING THE R10 R15 PUMPS 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 R15B HR3 6 Form No F3231 REV 12 00 ...

Page 2: ...rranty 5 Dimensions And Specifications 6 7 Installation 8 Preparation For Initial Start Up And Operation 9 Maintenance 10 11 12 Compressor Oil Specifications 13 Trouble Shooting Guide 14 15 16 Parts List 16 17 18 19 20 21 Constant Speed Head Unloader Kit 22 Operation And Adjustment Of Pilot Valves 23 Unit Hazard Decal Tags 24 25 26 Pump Hazard Decals Tags 27 Record Of Maintenance Service 28 29 30 ...

Page 3: ...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...

Page 4: ...per downstream equipment will cause serious injury whether air is supplied direct from the compressor source or to the breathing tanks for later use Any and all libilities for 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 without proper downstream filtration and purificaton will be discla...

Page 5: ... Limited Warranty CHAMPION warrants each new air compressor unit 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 accessor...

Page 6: ...U HR PUMP RPM APPROX PULLEY O D INCHES R 10D 125 1 1 2 11 0 660 3360 570 5 55 R 10D 175 1 1 2 10 5 625 3360 542 5 25 R 10D 125 2 14 8 875 4480 760 7 35 R 10D 175 2 14 1 835 4480 725 7 0 R 15B 125 3 14 5 565 6700 490 4 75 R 15B 175 3 12 8 505 6700 440 4 31 R 15B 125 5 21 9 868 12 000 750 7 35 R 15B 175 5 20 7 820 12 000 710 7 00 R 15B 175 7 1 2 30 2 1195 16 800 1035 9 75 All data is based on 1725 R...

Page 7: ... 6 10 6 14 10 14 10 6 4 Values in for Duplex Unit w one incoming power line to both motors PIPE SIZES FOR COMPRESSED AIR LINES R 10D R 15B Based on Clean Smooth Schedule 40 Pipe LENGTH OF PIPE LINES IN FEET 25 50 75 100 150 200 250 300 R 10D 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 R 15B 3 4 1 3 4 1 3 4 1 3 4 1 1 1 1 4 1 1 1 4 1 1 1 4 1 1 1 4 Values in for Duplex Unit Never use plastic pipe or improperly r...

Page 8: ...on or a pilot valve for continuous operation If a pilot valve is used the compressor must be equipped with head unloaders Control air must be piped from the air receiver to the pilot valve DANGER Do not install isolating valves betweencompressor outlet and air receiver This will cause excessive pressure if valve is closed and cause injury and equipment damage WARNING Always use an air pressure reg...

Page 9: ...onnect power leads to starter WARNING Do not attempt to operate compressor on voltage other than that specified on order or on compressor motor 2 Check compressor oil level Add oil as required See section on Oil Specifications 3 Inspect unit for any visible signs of damage that would have occurred in shipment or during installation 4 Activate main disconnect switch 5 Jog motor and check for proper...

Page 10: ...ENANCE 1 Clean dust and foreign matter from cylinder head motor fan blade air lines intercooler 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 tight...

Page 11: ...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 the un...

Page 12: ...preventing the compressor from reaching proper speed See BELTS above CHECK VALVE The check valve closes when the compressor stops operating preventing air from flowing out of the tank through the pressure release valve After the compressor stops operating if air continues to escape through the release valve it is an indication that the check valve is leaking This can be corrected by removing check...

Page 13: ... oxidation inhibitors specially formulated for reciprocating compressors Contact your distributor for information and purchase of this oil For temperatures below 32 degrees F use an ISO 68 compressor oil A separate list of acceptable oils can be obtained from the distributor s Service Department NOTES 1 Do not mix oil types weights or brands Consult factory for the use of synthetic lubricants 2 Fo...

Page 14: ...alve Pops Off Continuously M Compressor Cycles runs too Often N Starter Kicks Out POSSIBLE CAUSE OF PROBLEM N M L K J I H G F E D C B A 1 Main Switch and Fuses Open 1 2 Magnetic Starter Heater Coils Open 2 3 Magnetic Starter Tripped 3 4 Points in Pressure Switch Defective 4 5 Diaphragm in Pressure Switch Bad 5 6 Low Voltage 6 7 Motor Lubrication Inadequate 7 8 Excess Water in Air Receiver 8 9 Dirt...

Page 15: ... wire brush 9 V belts must be tight enough to transmit the necessary power to the compressor If too tight they will overload the 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 WARNING Disconnect unit from...

Page 16: ...cted flow of entering air To service filter remove wing nut metal cover and filter element Element may be blown clean with an air nozzle if moderately dusty Heavily fouled elements should be replaced Never clean element with fuel oil gasoline or flammable solvent 22 Cool running and long life can be assured by careful attention to crankcase oil Check frequently and change as indicated on compresso...

Page 17: ...686 M3590 M3590 M3590 M3590 M3590 M3590 M2686 M3590 M3590 M2686 M3590 M2686 M2686 M3590 M2686 P09315B P09315B P09315B M7009D M7009D M7009D M4309D M4309D M4309D M7009D M7009D M7009D M7009D P09315B P09315B M7009D M7009D M4309D M4309D M4309D M7009D M7009D M7009D P09315B M7009D M4309D M7009D P07981A Pulley P05607A Bushing P07981A Pulley P05607A Bushing P07981A Pulley P05607A Bushing P07981A Pulley P05...

Page 18: ...hick Gasket Gov Housing 010 Thick Gasket Gov Housing 015 Thick 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 NR80A M2343 SE1489 NR104 SE583B SE582 SE 592A M466 M2345 M912A SE590 SE587 RE10100A Z4593 M3473 Z12414A SE586B P07841A SE591 NR101 Z764 Gov Housing Screw Hex Head Cap Gasket Gov Housing Cover Plate Gov Baffle Spindle Gov Wt Gov Wt Pin Gov Wt...

Page 19: ...s 5 6 7 8 R 10D High Pressure side only Connecting Rod Bolt Connecting Rod Dipper Oil R 10D only Dipper Oil R 15B only 1 1 2 1 2 1 1 4 2 2 8 9 10 11 12 13 14 R1037 ZR154 ZP2709C R1021 R10102 Z797 Z798 Z9100 Z9101 Z799 Bearing Piston Pin Piston Low Pressure w Pin Piston High Pressure w Pin Pin Piston Ring Piston Pin Retaining RING SET HIGH PRESSURE PISTON RING SET LOW PRESSURE PISTON KIT HIGH PRESS...

Page 20: ...et Valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 M2100 RE760 RE1062 RE757A P04136 RE102E P12303B P09669C P12302B P05005A SE542 SE541 P04999A P05050A P03592A P09704A Z812 Z813 Z5117 Z115 Z5155 Z5156 Cage Exhaust Valve Spring Valve Disc Valve Seat Exhaust Valve Gasket Valve Manifold LP Exhaust Manifold HP Exhaust Manifold LP Intake Mani...

Page 21: ...PART NO NAME REQ 1 2 3 4 5 6 7 M2863 ZSB250A M2864 ZUB375 M2864 M2868 Z9140 Compression Fitting Tube Unloading w Fittings Compression Fitting Breather Tube w Fittings Compression Fitting Compression Fitting Intercooler w Fittings 1 1 1 1 1 1 1 ...

Page 22: ...ose found in the regular parts list Z9144 CAPTURED UNLOADER VALVE R 10D R 15B REF NO TOTAL REQ D PART NO LOW PRESSURE 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1 Z6312 P09670C P02306B P09923A P02547A Z4877 P09085A P09084A P09086A P09083A LP Intake Manifold Group includes 1 2 3 4 LP Intake Manifold Cylinder Unloader Piston O Ring LP Valve Assembly includes 6 7 8 9 Unloader Finger Unloader Spring Locknut ...

Page 23: ... pressure at which the Pilot Valve is on or off is controlled by the spring which has been installed at the factory A small adjustment can be made in the field by changing the spring force by compressing the spring more or less with the adjusting screw provided on the Pilot Valve COMPRESSOR PILOT VALVEPRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running 1 Loosen ...

Page 24: ...ructions Dual Control Valve Low Oil Safety Control Automatic Tank Drain Service Information For Optional Parts P09879A P09376B P09430B P09750B P04934A P09384B P09752B P09373B P09758A P04983A M1736 P04518A M422 P09388A P04988A P09755B P05381A P02134A M653 P04995A UNIT HAZARD TAG LISTING U V W IMPORTANT Electrical Specs DANGER Valve Instructions WARNING Read Owners Guide P05257A P09852A P04996A PUMP...

Page 25: ...25 UNIT HAZARD DECALS TAGS A B C D E F G H I J ...

Page 26: ...26 K L M N O P Q R S T U V W 140 175 PSIG ...

Page 27: ...27 PUMP HAZARD DECALS TAGS 1 2 3 4 5 6 ...

Page 28: ...VICE DAILY CHECK OIL LEVEL DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS MONTHLY INSPECT AIR SYSTEM EVERY 3 MONTHS CHANGE OIL INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 29: ...VICE DAILY CHECK OIL LEVEL DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS MONTHLY INSPECT AIR SYSTEM EVERY 3 MONTHS CHANGE OIL INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 30: ...VICE DAILY CHECK OIL LEVEL DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS MONTHLY INSPECT AIR SYSTEM EVERY 3 MONTHS CHANGE OIL INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 31: ......

Page 32: ...1 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 Copyright 8 2000 Gardner Denver Inc Printed in U S A FOR PARTS REFER TO PARTS DEPOT LIST ACCOMPANYING THIS MANUAL ...

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