Champion Air Compressor Problem

[candrews]

I recently purchased a model HR5-8 with an R15B pump and a Baldor 5hp 3 phase motor, not hooked up so did not hear running although the seller said it did. I paid $150 for it so it was worth the gamble. I got lucky and found the same Baldor 184t frame motor 5hp single phase motor used for $150. I installed the motor and the pressure pumped fine but the air pissed out the automatic tank drain and was not unloading. I replaced all the parts in the ATD but the air still pssed out the same tube. Cleaned the governor housing unloader valve, same result. Replaced the unloader valve, same result. Cleaned the stuck open tank check valve, new result. The air pisses out the ATD tank drain tube while motor and pump are running but onloads and stops when shut down. Took unloader valve apart and cleaned and turned release valve plunger around but same result. The plunger is stepped and was in small end facing ball from pump side. My parts illustration shows the plunger in from the outside but can only be put on the inside. What can I be missing here? The air pisses out when running and the manual states to replace the release valve assembly to correct this problem. Thanks in advance to any assistance with this problem.

 

[Monkey Milk]

unloader valves are adjustable for pressure if you didn't know. I wonder if you have rust in the tank that's making the valves stay open. Take a picture, would like to see how it's set up.

 

[Kevski]

Sounds like the flyweights may be jammed, and thus not actuating the unloader plunger. That, or you're not spinning it fast enough.

 

[candrews]

The tank seems to be clean of rust and the ball does not get dirty after a few disassemblies. The weights move freely and I have not changed the pullys only the motor with the same HP and RPM. I have not cleaned the valves yet as I was trying to get it running correctly first but intend to once running. I have no idea how it was maintained by previous owner but the air cleaner was a mess which indicates to me the valves must need attention. I dont see why that would cause this issue though.

 

[candrews]

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[Monkey Milk]

can you point out what you are calling the "auto tank drain""ADV". All I see is a ball valve for the tank drain.

 

[Monkey Milk]

Never mind, I blew the pic up and seen what your talking about.




When the compressor pump stops, this Tank Drain Valve uses the "air blow-off" from the piston cylinders to operate this valve and discharge condensate water that has accumulated in the compressor tank.

Every time the pumps cycles on and off, water is drained from the tank.





Ok, I don't have one of these or never worked on this type of auto drain but from my understanding it's a valve that uses "air blow-off "to open this drain valve for a brief moment to drain. Sounds simple enough?

Have you tried to remove and block off the copper tube that runs to this valve under pressure? This would eliminate a leaking ADV valve(I know you replaced it).

If all is well then I would move into the unloader valve area.

I don't see how the valves would cause this.

 

[candrews]

Problem solved. It seems the new unloader vave with the cap, spring, ball and plunger were different from older models and newer ones. The older model was 1/8" shorter on the large end of the plunger. I called pacific air compressors where I purchased the part and the fellow I talked to on the phone knew the problem right away. He suggested to grind a bit off but I saved the old plunger and reused it. I should have known when I matched up the parts, but thought it may have worn down over time and forgot it was shorter when I kept diagnosing different causes. Tha bottom line is I should have cleaned the tank check valve first. Then rebuilt the ATD as the diaghram was torn and it most likely would have been good to go.