PL Series 2-Stage Pressure Lubricated Air Compressor

PL Series 2-Stage Pressure Lubricated Air Compressor
OPERATION/MAINTENANCE
MANUAL & PARTS LIST
PL Series 2-Stage Pressure Lubricated Air
Compressor & Units Featuring the PL15A Pump
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.
C354-B
(Ref. Drawing)
MODEL VPL5-6 UNIT
Form No. F92193PLA
VER: 18 07/01/2009
C326-A
(Ref. Drawing)
MODEL PL15A COMPRESSOR
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE CHAMPION COMPRESSOR
PARTS AND SUPPORT SERVICES
Champion Compressor genuine parts, manufactured to design tolerances, are developed for optimum
dependability – specifically for Champion compressor systems. Design and material innovations are the
result of years of experience with hundreds of different compressor applications. Reliability in materials
and quality assurance are incorporated in our genuine replacement parts.
Your authorized Champion Compressor distributor offers all the backup you’ll need. A worldwide network
of authorized distributors provides the finest product support in the air compressor industry.
Your authorized distributor can support your Champion air compressor 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 skilled in compressor maintenance 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 Champion Air Compressor distributor, refer to the yellow
pages of your phone directory or contact:
Factory:
Champion
1301 North Euclid Avenue
Princeton, IL 61356
Phone: ((815) 875-3321
Fax:
(815) 872-0421
E-Mail: Champion@Championpneumatic.com
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, HORSEPOWER and SERIAL NUMBER (see
nameplate on unit). All orders for Parts should be placed with the nearest authorized distributor.
Order by part number and description. Reference numbers are for your convenience only.
2
TABLE OF CONTENTS
_______________________________________________________
Subject
Page
Maintain Compressor Reliability ............................................................................................................2
Safety And Operation Precautions .........................................................................................................4
Explanation Of Safety Instruction Symbols And Decals .........................................................................5
Introduction .............................................................................................................................................6
Warranty .................................................................................................................................................6
Dimensions And Specifications ..............................................................................................................7
Installation............................................................................................................................. 8, 9 10 & 11
Operation ..................................................................................................................................... 11 & 12
Maintenance .......................................................................................................................... 13, 14 & 15
Compressor Pilot Valve Differential Pressure Adjustment ...................................................................16
Compressor Oil Specifications..............................................................................................................17
Torque Valves.......................................................................................................................................17
Trouble Shooting Guide............................................................................................................... 18 & 19
Unit Repair Parts List ................................................................................................................20 thru 23
Compressor Repair Parts List...................................................................................................24 thru 30
Unit Hazard Decal Listing .....................................................................................................................31
Unit Hazard Decals ...............................................................................................................................32
Pump Hazard Decals ............................................................................................................................33
Record Of Maintenance Service.................................................................................................. 34 & 35
3
SAFETY AND OPERATION PRECAUTIONS
___________________________________________________________________________________
Because an air compressor is a piece of machinery with moving and rotating parts, the same precautions
should be observed as with any piece of machinery of this type where carelessness in operation or
maintenance is hazardous to personnel. In addition to the many obvious safety rules that should be
followed with this type of machinery, the additional safety precautions as 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.
Read all instructions completely before operating air compressor or unit.
For installation, follow all local electrical and safety codes, as well as the National Electrical Code
(NEC) and the Occupational Safety and Health Act (OSHA).
Electric motors must be securely and adequately grounded. This can be accomplished by wiring
with a grounded, metal-clad raceway system to the starter; by using a separate ground wire
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.
Make certain that the power source conforms to the requirements of 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.
Do not attempt to remove any compressor parts without first relieving the entire system of
pressure.
Do not attempt to service any part while machine is in an operational mode.
Do not operate the compressor at pressures in excess of its rating.
Do not operate compressor at speeds in excess of its rating.
Periodically check all safety devices for proper operation. Do not change pressure setting or
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 cleaning the air inlet filter or element and other parts.
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.
Do not operate the compressor without guards, shields and screens in place.
Do not install a shut-off valve in the discharge line, unless a pressure relief valve, of proper design
and size, is installed in the line between the compressor unit and shut-off valve.
Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic
fumes.
Be careful when touching the exterior of a recently run motor - it may be hot enough to be painful
or cause injury. With modern motors this condition is normal if operated at rated load - modern
motors are built to operate at higher temperatures.
Inspect unit daily to observe and correct any unsafe operating conditions found.
Do not "play around" with compressed air, nor direct air stream at body, because this can cause
injuries.
Compressed air from this machine absolutely must not be used for food processing or breathing
air without adequate downstream filters, purifiers and controls.
Always use an air pressure regulating device at the point of use, and do not use air pressure
greater than marked maximum pressure of attachment.
Check hoses for weak or worn condition before each use and make certain that all connections
are secure.
Always wear safety glasses when using a compressed air blowgun.
The user of any air compressor package manufactured by Champion is hereby warned that failure to
follow the preceding Safety and Operation Precautions can result in injuries or equipment damage.
However, Champion does not state as fact or does not mean to imply that the preceding list of Safety and
Operating Precautions is all inclusive, and further that the observance of this list will prevent all injuries or
equipment damage.
4
EXPLANATION OF SAFETY INSTRUCTION SYMBOLS AND DECALS
DANGER
Indicates immediate hazards which will result in severe injury or death.
WARNING
Indicates hazards or unsafe practice which could result in severe injury or death.
CAUTION
Indicates hazards or unsafe practice which could result in damage to the Champion
compressor or minor injury.
NOTICE
Notice is used to notify people of installation, operation or maintenance information which is
important but not hazard-related.
SAFETY AND OPERATION PRECAUTIONS
OBSERVE, UNDERSTAND AND RETAIN THE INFORMATION GIVEN IN THE SAFETY
PRECAUTION DECALS AS SHOWN IN THE PARTS LIST SECTION
DANGER
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 the manufacturer.
WARNING
The use of this compressor as a booster pump and/or to compress a medium other than
atmospheric air is strictly non-approved and can result in equipment damage and/or injury.
CAUTION
This unit may be equipped with special options which may not be included in this manual. User
must read, understand and retain all information sent with special options.
5
INTRODUCTION
______________________________________________________________________
Champion PL Series compressors are the result of advanced engineering and skilled manufacturing. To
be assured of receiving maximum service from this machine the owner must exercise care in its operation
and maintenance. This book is written to give the operator and maintenance department essential
information for day-to-day operation, maintenance and adjustment. Careful adherence to these
instructions will result in economical operation and minimum downtime.
WARRANTY
Champion Five Year Warranty
"PL" Series Compressors
CHAMPION warrants each new compressor pump manufactured by CHAMPION, mounted on a factory
assembled unit, to be free from defects in material and workmanship under normal use and service for a
period of sixty (60) months from date of installation or sixty-six (66) months from date of shipment by
CHAMPION or CHAMPION distributor, whichever may occur first. Applies to the compressor pump
only, excluding head valves. Valves, controls and accessories are warranted for the first year only.
Compressor pumps purchased separately would carry a one year warranty.
This five year extended warranty will be prorated over the 5 years as follows:
First Year
Second Year
Third Year
Fourth Year
Fifth Year
-
100% Allowance, Parts and Labor
90% Allowance, Parts and Labor
80% Allowance, Parts and Labor
70% Allowance, Parts and Labor
60% Allowance, Parts and Labor
Applies to CHAMPION logo, tank or base mounted complete compressors only.
Express 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 accessories furnished to CHAMPION by
third parties, such as ELECTRIC MOTORS, GASOLINE ENGINES and CONTROLS, which are warranted
only to the extent of the original manufacturer's warranty to CHAMPION. To have warranty consideration,
electric motors must be equipped with thermal overload protection.
The extended five year warranty will apply to ASME air receivers provided they are installed on rubber
vibro isolator pads or approved equivalent.
When a compressor pump, or component is changed or replaced during the warranty period, the
new/replaced item is warranted for only the remainder of the original warranty period.
Repair, replacement or refund in the manner and within the time provided shall constitute CHAMPION'S
sole liability and your exclusive remedy resulting from any nonconformity or defect. CHAMPION SHALL
NOT IN ANY 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 OTHER WARRANTY OR REPRESENTATION OF ANY KIND, EXCEPT THAT
OF TITLE, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OR
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY EXPRESSLY
DISCLAIMED. NO SALESMAN OR OTHER REPRESENTATIVE OF CHAMPION HAS AUTHORITY TO
MAKE ANY WARRANTIES
6
TWO STAGE AIR COMPRESSORS - MODEL PL15A
DIMENSIONS
ITEM
A
B
C
D
E
F
I
J
K
L
M
N
O
P
Q
R
C-327-A
(Ref. Drawing)
PL15A
Base-Width
Bolt Down-Width
Bolt Down to Edge
Base to Crank Ctr
Overall Width
Overall Height
Bolt Down Hole Dia.
Base-Depth
Bolt Down Depth
Bolt Down to Edge
Bolt Hole to Wheel (Max.)
Flywheel Width
Crank Diameter
Flywheel Diameter
Flywheel Grooves
Overall Depth
10
4-3/8
5/8
5-1/2
16-7/8
23-1/4
15/32
7-1/2
5-3/4
7/8
3-3/16
2-1/2
1-5/16
16-1/2
2VB
19-7/8
NOTE: H.P. Exhaust Opening 3/4" Tubing.
Flywheel Rotation – Clockwise when viewed
from front, flywheel to rear.
SPECIFICATIONS
MODEL
BORE & STROKE
(INCH)
NO. OF
CYLINDERS
OIL
CAPACITY
(QTS)
WEIGHT
(LBS)
MAXIMUM
PRESSURE
(PSIG)
CU
FT./REV.
MIN./MAX.
RPM.
PL15A
4-5/8" & 2-1/2" x 3"
2
2
109
250
.02914
375/1050
Standard units are set up for 175 PSIG operation. High pressure units are set for the higher 250 PSIG
range and come with the special tanks, pressure switches, pressure relief valves, pulleys and pilot valves.
To determine the pressure setting of a particular compressor check the pressure setting decal located on
the air tank.
Note that 175 PSIG units cannot be converted to safely operate at pressures above 200 PSIG unless all
the above mentioned components including the air tank are replaced with 250 PSIG rated items. Refer to
parts list for applicable part numbers.
PERFORMANCE
PUMP
OUTPUT
PRESS.
PSIG
MOTOR
H.P.
PUMP
RPM
DISPL.
CFM
COOLING
AIR FLOW
CFM
HEAT
REJECTION
BTU/HR
APPROX.
PULLEY O.D.,
INCHES
PL15A
PL15A
PL15A
PL15A
PL15A
PL15A
175
175
175
250
250
250
3
5
7.5
3
5
7.5
440
710
990
380
640
870
12.8
20.7
28.7
11.0
18.5
25.5
505
800
1195
454
740
1087
6700
12,000
16,800
6,700
12,000
16,800
4.31
7.00
9.75
375
6.75
8.95
All data is based on 1725 RPM electric motors as a power source.
Pulley Dia. (approx.) = Compressor RPM x Flywheel Dia.
Motor or Engine RPM
7
INSTALLATION
WARNING
Do not operate unit if damaged during shipping, handling or use. Operating unit if damaged
may result in injury.
1.
Permanently installed compressors must be located in a clean, well ventilated dry room so
compressor receives adequate supply of fresh, clean, cool and dry air. It is recommended that a
compressor, used for painting, be located in a separate room from that area wherein body sanding
and painting is done. Abrasive particles or paint, found to have clogged the air intake filters and
intake valves, shall automatically void warranty.
2.
Compressors should never be located so close to a wall or other obstruction that flow of air
through the fan blade flywheel, which cools the compressor, is impeded. Permanently mounted
units should have flywheel at least 12" from wall.
3.
Place stationary compressors on firm level ground or flooring. Permanent 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. It is recommended that unit be
set on optional vibro-isolator pads. Tanks bolted directly to a concrete floor without isolators will
not be warranted against cracking. Champion vibro-isolators or approved equivalent must be
installed for extended warranty to apply to ASME receivers.
4.
If installing a bare pump, or base mounted unit, make certain the pressure limiting controls are
properly installed and operational. The PL model pump is supplied with a pilot valve, but a
pressure switch must be provided by customer for start/stop operation. The hydraulic unloading
system requires a control air pressure line from the air receiver to be connected to the pilot valve
fitting on the pump.
5.
A properly sized air check valve must be installed in the discharge piping between the compressor
outlet and the inlet of any receiver tank(s) in the system.
DANGER
Do not install isolating valves between compressor 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 regulating device at the point of use. Failure to do so can result in
injury or equipment damage.
CAUTION
•
•
•
Do not install in an area where ambient temperature is below 32 degrees F or
above 100 degrees F.
Do not install unit in an area where air is dirty and/or chemical laden.
Unit is not to be installed outdoors.
8
INSTALLATION (CONT’D)
ELECTRICAL POWER SUPPLY
It is essential that he power supply and the supply wiring are adequately sized and that the voltage
correspond to the unit specifications. Branch circuit protection must be provided at installation a
specified in the National Electrical Code.
All wiring should be preformed by a licensed electrician or electrical contractor. Wiring must meet
applicable codes for area of installation. The table gives recommended wire sizes based on the
1999 NEC.
WIRE SIZE (AWG) – 75°C COPPER – 30°C AMBIENT
MOTOR
HP
3
5
7½
3 PHASE
1 PHASE
200/208V
230V
460V
575V
115V
208V
14
14
14
14
8
10
10(8)
12(8)
14(12)
14
-8(6)
8(6)
10(6)
14(10)
14(10)
-6(3)
Values in ( ) for Duplex Unit w/one incoming power line to both motors.
230V
10
8(6)
6(4)
All models require a properly sized magnetic starter as specified in the National Electric Code (NEC).
See Figure 1-1 for simplex wiring diagram and Figure 1-2 for duplex wiring diagram.
If ordered with a factory mounted magnetic starter, compressor is wired at factory. It is necessary only to
bring lines from a properly sized disconnect switch to the magnetic starter mounted on the unit.
305CAS546-B
(Ref. Drawing)
304CAS546-A
(Ref. Drawing)
Figure 1-1 Simplex Wiring Diagram
9
ELECTRICAL POWER SUPPLY (CONT’D)
311CAD546-B
(Ref. Drawing)
Figure 1-2 Duplex Wiring Diagram
312CAD546-B
(Ref. Drawing)
CAUTION
Wiring must be such that when viewing compressor from opposite shaft end, rotation of shaft is clockwise as
shown by arrow on guard. Wrong direction rotation for any length of time will result in damage to compressor.
10
GROUNDING INSTRUCTIONS
This product should be connected to a grounded, metallic, permanent wiring system, or an
equipment-grounding terminal or lead on the product.
AIR LINE PIPING
Connection to air system should be of the same size, or larger, than discharge pipe out of unit.
The table gives recommended minimum pipe sizes. A union connection to the unit and water
drop leg is recommended. Install a flexible connector between the discharge of the unit and the
plant air piping. Plant air piping should be periodically inspected for leaks using a soap and water
solution for detection on all pipe joints. Air leaks waste energy and are expensive.
Minimum Pipe Sizes For Compressor Air Lines
(Based on clean Smooth Schedule 40 Pipe)
MODEL
PL15A
25’
3/4” (1”)
50’
3/4” (1”)
100’
3/4” (1”)
200’
1” (1-1/4”)
300’
1” (1-1/4”)
Values in ( ) are for duplex unit.
WARNING
Never use plastic pipe or improperly rated metal pipe. Improper piping material can burst and
cause injury or property damage.
OPERATION
This compressor has been inspected, thoroughly tested and approved at the factory. For this unit to give
long satisfactory service it must be installed and operated properly. This compressor has been designed
for a 80%/ON – 20%/OFF duty cycle.
Simplex units have a pressure switch that senses changes in receiver pressure and automatically starts
and stops the compressor at preset pressure limits. If the receiver pressure falls below the cut-in
pressure setting of the pressure switch the compressor will run until the cut-out pressure setting of the
pressure switch has been reached.
Duplex units have lead and lag pressure switches and an automatic alternating system to evenly
distribute the load between the two compressors. The pressure switches sense changes in receiver
pressure and automatically start and stop the compressor at preset pressure levels. If the receiver
pressure falls below the cut-in pressure setting of the lead pressure switch but remains above the cut-in
pressure setting of the lag pressure switch, only one compressor will run until receiver pressure reaches
the cut-out pressure of the lead pressure switch. The next time the pressure in the receiver drops, the
system automatically starts the compressor that was idle. If the receiver pressure falls below the cut-in
pressure setting of the lag pressure switch, both compressors run until receiver pressure reaches the cutout pressure setting of the lead pressure switch.
PL15A models are equipped with a needle valve, pilot valve and head unloaders to provide continuous
run capabilities. The pilot valve acts as an automatic air switch allowing air to flow from the receiver to
the head unloader mechanism, thus actuating it. To operate unit in continuous run, open needle valve
located next to pilot valve. The pilot valve is now able to sense receiver pressure. When the receiver
pressure reaches the cut-out pressure setting of the pilot valve, the pilot valve opens and air is released
to the unloader mechanism. The compressor stops compressing air and runs unloaded until the cut-in
pressure setting of the pilot valve has been reached. At this time air released from the unloader
mechanism and the compressor starts compressing again. Continuous run is recommended if motor
starts exceed 8 starts/hour.
11
OPERATION (CONT’D)
Initial Start Up
1. Inspect unit for any visible signs of damage that would have occurred in shipment or during
installation.
2. Pull main disconnect switch to unit to assure that no power is coming into the unit. “Lock Out” or “Tag
Out” switch. Connect power leads to start.
WARNING
Do not attempt to operate compressor on voltage other than that specified on order or on
compressor motor.
3. Check compressor oil level. Add oil as required. See “Compressor Oil Specifications” Section.
NOTE: Do not mix oil type, weights or brands.
4. Activate main disconnect switch.
5. “Jog” motor and check for proper rotation by direction arrow. If rotation is wrong, reverse input
connections on the magnetic starter.
6. Close receiver outlet hand valve and start.
7. With receiver hand valve closed, let machine pump up to operating pressure. At this stage the
automatic controls will take over. Check for proper cycling operation.
8. This compressor is equipped with a pressure lubrication system. The oil pressure gauge is located
on the bearing housing on the front of the crankcase. During operation oil pressure should normally
be between 15 PSIG and 30 PSIG. Oil pressure can drop to 10 PSIG with no adverse operation.
Oil pressure is maintained internally in the oil pump, so no adjustment is required.
9. Check for proper operation of any options. Refer to individual option instruction sheet.
10. When the initial run period has shown no operating problems, shut unit down and recheck oil level.
11. Open receiver hand valve. The air compressor unit is now ready for use.
WARNING
This unit can start automatically without warning.
12
GUIDE TO MAINTENANCE
For Service contact an authorized Champion distributor. All requests should include model number
and serial number. To obtain reliable and satisfactory service, this unit requires a consistent
preventive maintenance schedule. Maintenance schedule form is included to aid in keeping the
proper records.
WARNING
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 all
air pressure in unit is relieved. Failure to do this may result in injury or equipment damage.
DAILY MAINTENANCE
1.
Check oil level of compressor. Add Champlub recip lubricant as required. See “Compressor Oil
Specifications” Section. NOTE: Do not mix oil type, weight, or brands.
2.
Drain moisture from tank by opening tank drain cock located in bottom of tank. Do not open drain
valve if tank pressure exceeds 25 PSIG.
3.
Turn off compressor at the end of each day's operation. Turn off 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.
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 tightness. The V-belts must be tight enough to transmit the necessary power to
the compressor. Adjust the V-belts as follows:
a. Remove bolts and guard to access compressor drive.
b. Loosen mounting hardware which secures motor to base. Slide motor within slots of baseplate
to desired position.
c. Apply pressure with finger to one belt at midpoint span. Tension is correct if top of belt aligns
with bottom of adjacent belt. Make further adjustments if necessary.
d. Check the alignment of pulleys. Adjust if necessary.
e. Tighten mounting hardware to secure motor on base.
f. Re-install guard and secure bolts.
WARNING
Never operate unit without belt guard in place. Removal will expose rotating parts which can
cause injury or equipment damage.
13
EVERY 90 DAYS OR 500 HOURS MAINTENANCE
1. Change crankcase oil and oil filter. Use only Champlub recip lubricant.
2. Check entire system for air leakage around fittings, connections, and gaskets, using soap solution
and brush.
3. Tighten nuts and cap screws as required.
4. Check and clean compressor valves as required. Replace when worn or damaged parts.
CAUTION
Valves must be replaced in original position. Valve gaskets should be replaced each time
valves are serviced.
5. Pull ring on all pressure relief valves to assure proper operation.
GENERAL MAINTENANCE NOTES
PRESSURE RELIEF VALVE: The pressure relief valve is an automatic pop valve. Each valve is properly
adjusted for the maximum 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, or drop pressure in line. Do
not readjust.
PRESSURE SWITCH: The pressure switch is automatic and will start compressor at the low pressure
and stop when the maximum pressure is reached. It is adjusted to start and stop compressor at the
proper pressure for the unit on which it is installed. Do not readjust.
BELTS: Drive belts must be kept tight enough to prevent slipping. If belts slip or squeak, see V-belt
maintenance in preceding section.
CAUTION
If belts 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 valves and clean thoroughly, using compressed air and a soft
wire brush. After cleaning exceptional care must be taken that all parts are replaced in exactly the
same position and all joints must be tight or the compressor will not function properly. When all
valves are replaced and connections tight, close hand valve at tank outlet for final test. Valve
gaskets should be replaced each time valves are removed from pump.
14
GENERAL MAINTENANCE (Cont'd.)
HYDRAULIC UNLOADER: This compressor is equipped with an unloading device operated by oil
pressure. When the compressor is turned off, the unloader will open resulting in a short burst of air
from the unloader (released through the intake filter). When the compressor is restarted, as soon
as the oil pressure reaches normal operation range (between 15 and 30 PSIG) the unloader valve
closes and the compressor begins to pump air. This unloader system provides loadless starting for
long motor life and has the added feature of preventing the compression of air should the oil pump
fail. In the event of loss of oil pressure, the compressor would run in an “unloaded” state only, until
correction of the oil pressure is made.
CHECK VALVE: The check valve closes when the compressor stops operating, preventing air from
flowing out of the tank through the pressure release. 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 valve and cleaning disc and seat. If check valve is worn
badly, replace same.
WARNING
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 is provided to protect against interstage over pressure
and is factory set for maximum pressure of 75 PSIG. DO NOT RESET
If the pressure relief valve pops, it indicates trouble. Shut down the unit immediately and determine
and correct the malfunction. Inspect the head valves. Serious damage can result if not corrected
and can lead to complete destruction of the unit. Tampering with the interstage pressure relief
valve, or plugging the opening destroys the protection provided and voids all warranty.
COMPRESSOR LUBRICATION: Fill crankcase to proper level as indicated by oil sight gauge. Keep
crankcase filled as required by usage. It is recommended that only Champlub recip lubricant be
used. This is a 30-weight, non-detergent industrial oil with rust and oxidation inhibitors specially
formulated for reciprocating compressors. Do not mix oil types, weights or brands.
MOTOR LUBRICATION: Long time satisfactory operation of an electric motor depends in large measure
on proper lubrication of the bearings. Bearing grease will lose its lubricating ability overtime, not
suddenly. Refer to the motor manufacturer’s instructions for the type of grease and lubrication
intervals.
PILOT VALVE: The pilot valve actuates the head unloader mechanism to provide a means of stopping
or starting the compression of air by the compressor without stopping or starting the electric motor.
15
COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT
Proceed with the following instructions while compressor is running:
1. Loosen locknut (4) and back off several turns. Do not turn differential pressure adjustment nut (3).
2. Check reading on the tank pressure gauge. Set the compressor maximum pressure by
turning threaded cap (1) clockwise to increase pressure or counter clockwise to decrease
pressure. Pressure setting must be 5 psig less than setting of pressure switch.
3. After pressure is set, tighten locknut (4). Be careful not to move threaded cap (1).
COMPRESSOR PILOT VALVE DIFFERENTIAL PRESSURE ADJUSTMENT
Proceed with the following instructions while compressor is running.:
1. Loosen locknut (2) and back off several turns.
2. Check reading on the tank pressure gauge. Set the pressure to 30 psig differential (unload at 170
psig, reload at 140 psig). Turn nut (3) clockwise to increase differential pressure or
counterclockwise to decrease differential pressure.
3. After pressure is set, tighten locknut (2). Be careful not to move nut (3).
B980-B
(Ref. Drawing)
16
COMPRESSOR OIL SPECIFICATIONS
Compressors are factory filled with CHAMPLUB hydrocarbon based recip lubricant. This is an ISO 100
non-detergent industrial lubricant with rust and oxidation inhibitors specially formulated for reciprocating
compressors. It is recommended this compressor be maintained using thbis oil for ambient temperatures
above 32°F.
CHAMPLUB synthetic is a premium grade diester based synthetic lubricant providing excellent
performance in high temperature applications.
CAUTION
Do not mix oil types, weights or brands.
CAUTION
“Emulsification of oil (white milky substance) indicates unsafe accumulation of moisture and
may be evidence compressor is oversized for application. Failure to promptly consult your
local distributor, or Champion Customer Service, can be grounds to deny warranty.”
NOTES:
1. Normal break-in period of Champion air compressors is 25 hours.
2. For the first 100 hours of compressor operation, a careful and regular check of the oil level should
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 compressor for 200 hours.
5. Stop compressor and thoroughly drain the synthetic lubricant.
6. Add a full charge of synthetic lubricant.
7. Compressor now ready to run for extended period before next lubricant change.
LUBRICANT
CHAMPLUB
DESCRIPTION
1 – Quart Case (12/case)
1 – Gallon Case (4/case)
5 – Gallon Pail
55 – Gallon Drum
PART NUMBER
P09479A
P08909A
P08908A
P08907A
CHAMPLUB SYNTHETIC
DESCRIPTION
1 – Quart Case (12/case)
1 – Gallon Case (4/case)
5 – Gallon Pail
55 – Gallon Drum
PART NUMBER
P13179A
P13180A
P11506A
P13181A
TORQUE VALVES
SPECIFIC APPLICATION
BEARING HOUSING BOLT
CYLINDER FLANGE BOLT
CONNECTING ROD BOLT
MANIFOLD BOLT
FLYWHEEL BOLT
FASTENER SIZE & THREAD
3/8 – 16
7/16 – 20
5-16 – 18
3/8 – 16
1/2 – 13
17
TORQUE
INCH-POUNDS
400
400
230
200
600
TROUBLE SHOOTING CHART FOR COMPRESSOR
WARNING
Always disconnect unit from power supply and relieve all pressure from air tank before performing any
maintenance. “Tag Out” or “Lock Out” all power sources. Failure to do so may result in equipment damage or
injury.
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
Motor will not start.
Starter trips repeatedly.
Possible Cause(s)
Main switch and fuses open.
1.
2.
Starter heater coils open.
2.
3.
Starter tripped
3.
4.
Defective pressure switchcontacts will not close
4.
5.
Low voltage.
5.
1.
Improperly adjusted pressure switch.
1.
Warning – Relieve tank pressure
before servicing.
Check with voltmeter. Be sure
voltage corresponds to unit
specifications.
Adjust or replace.
2.
Faulty check valve.
2.
Warning – Relieve tank pressure
before servicing.
Clean or replace
Tank pressure builds up quickly.
Discharge pressure relief valve pops
off while compressor is running.
Compressor will not unload
Excessive belt wear.
Compressor runs hot.
Check all fuses and switches. Check
for loose or faulty wires.
Check overload relay in starter.
Reset starter.
Reset starter. If starter trips
repeatedly, have electrical system
inspected by an electrician.
Repair or replace pressure switch.
4.
Incorrect fuse size or magnetic starter
heaters.
Low voltage.
5.
1.
2.
3.
Defective motor.
Air leaks.
Dirty air filter.
Defective compressor valves
5.
Warning – Relieve tank pressure
before servicing.
Be sure that fuses and heaters are
properly rated.
Check with voltmeter. Be sure
voltage corresponds to unit
specifications.
Replace motor.
1.
2.
3.
Tighten fittings.
Clean or replace.
Install new valve plate assembly.
1.
1.
2.
Excessive water in tank.
Wrong pressure switch setting.
Defective ASME relief valve.
1.
1.
2.
3.
Tank pressure builds up slowly.
Corrective Action
1.
3.
4.
1.
2.
3.
1.
2.
1.
Wrong pilot valve setting.
Defective pilot valve.
Lack of air to pilot valve..
Pulley out of alignment.
Belts too tight or too loose.
Improper flywheel rotation
1.
2.
3.
1.
2.
1.
2.
3.
4.
Defective compressor valves.
Dirty air filter.
Dirty cylinder and/or intercooler.
2.
3.
4.
Drain tank.
Adjust to correct setting.
Replace valve.
Warning – Relieve tank pressure
before servicing.
Adjust to correct setting
Replace pilot valve.
Open needle valve to pilot valve.
Realign motor pulley.
Adjust belt tension.
Check for correct rotation.
(Counter clockwise when viewed
from drive side.
Install new valve plate assembly.
Clean or replace.
Clean cylinder fins and/or intercooler.
Interstage pressure relief valve pops off.
1.
Defective compressor valves.
1.
Install new valves.
Excessive oil consumption.
1.
2.
3.
4.
5.
Dirty air filter.
Wrong oil viscosity.
Oil leaks.
Worn piston rings.
Scored cylinder
1.
2.
3.
4.
5.
Clean or replace.
Refill with proper viscosity oil.
Tighten bolts. Replace gaskets.
Replace rings.
Replace cylinder.
18
Troubleshooting Chart (cont’d)
Symptom
Low or loss of oil pressure
System does not alternate
(Duplex units only)
Possible Cause(s)
Corrective Action
1.
2.
Low crancase level.
Oil pickup screen clogged.
1.
2.
3.
1.
Faulty oil pump..
Starter tripped.
3.
2.
Loose wiring in alternator.
3.
4.
Defective alternator.
Defective motor.
19
1.
2.
3.
4.
Check oil level. Add oil if required.
Drain oil from crankcase.
Remove oil pickup screen and clean.
Reinstall screen and all clean oil to
crankcase.
Replace oil pump.
Reset starter. If starter trips
repeatedly, have electrical system
inspected by an electrician.
Check and tighten all wiring
connections.
Replace alternator.
Replace motor.
UNIT REPAIR PARTS ILLUSTRATION
MODELS: HPL3-6, HPL3-8, HPL3-12, HPL5-6, HPL5-8, HPL5-12, HPL7F-8 &
HPL7-12
C358-A
(Ref. Drawing)
REPAIR PARTS LIST
MODEL
HPL3-6
HPL3-8
HPL3-12
HPL5-6
HPL5-8
HPL5-12
HPL7F-8
HPL7F-12
1
Pump
PL15A
PL15A
PL15A
PL15A
PL15A
PL15A
PL15A
PL15A
2
Pressure Gauge
M519C
M519C
M519C
M519C
M519C
M519C
M519C
M519C
3
Belt Guard (Standard)
Z307
Z307
Z307
Z307
Z307
Z307
CC1016894
CC1016894
3
Belt Guard (With ACAC)
CC1016898
CC1016898
CC1016898
CC1016898
CC1016898
CC1016898
CC1016899
CC1016899
4
Drain Valve
VP1022988
VP1022988
VP1022988
VP1022988
VP1022988
VP1022988
VP1022988
VP1022988
5
Check Valve
P05822A
P05822A
P05822A
P05822A
P05822A
P05822A
P05822A
P05822A
6
Bucket High Drain
Z1541
Z1541
Z1541
Z1541
Z1541
Z1541
Z1541
Z1541
Pressure
Switch
175 PSIG
P14202A
P14202A
P14202A
P14202A
P14202A
P14202A
P14202A
P14202A
250 PSIG
P07422A
P07422A
P07422A
P07422A
P07422A
P07422A
P07422A
P07422A
8
Pressure
Relief Valve
175 PSIG
M2843
M2843
M2843
M2843
M2843
M2843
M2843
M2843
250 PSIG
M2845
M2845
M2845
M2845
M2845
M2845
M2845
M2845
9
Motor
3HP
3HP
3HP
5HP
5HP
5HP
7.5HP
7.5HP
10
Tank
175 PSIG
P01136D
P01164D
P01596D
P01136D
P01164D
P01596D
P01164D
P01596D
250 PSIG
P09374D
P07436D
P07434D
P09374D
P07436D
P07434D
P07436D
P07434D
M3590
M3590
CQM3756
M3590
M3590
CQM3756
M4309D
M4309D
M4309D
M7009D
M7009D
M7009D
P08083A
PULLEY
P09358A
BUSHING
P08083A
PULLEY
P09358A
BUSHING
P08083A
PULLEY
P09358A
BUSHING
M3590
P13912A
PULLEY
P05607A
BUSHING
CC1005979
PULLEY
P05607A
BUSHING
CQM3756
P13912A
PULLEY
P05607A
BUSHING
CC1005979
PULLEY
P05607A
BUSHING
7
11
Isolation Valve
12
Pulley
12
13
Pulley
Belts
175 PSIG
250 PSIG
P11923A
P11923A
P11923A
175 PSIG
5L650(2)
5L650(2)
5L650(2)
5L680(2)
5L680(2)
5L680(2)
B68 (2)
B68 (2)
250 PSIG
5L650(2)
5L650(2)
5L650(2)
5L680(2)
5L680(2)
5L680(2)
5L690 (2)
5L690 (2)
20
UNIT REPAIR PARTS ILLUSTRATION
MODELS: VPL3-6, VPL3-8, VPL3-12, VPL5-6, VPL5-8, VPL5-12, VPL7F-8, &
VPL7F-12
1
13 (NOT SHOWN)
3
12 (NOT SHOWN)
9
7
8
5
11
2
10
6
C357-B
(Ref. Drawing)
4
REPAIR PARTS LIST
MODEL
VPL3-6
VPL3-8
VPL3-12
VPL5-6
VPL5-8
VPL5-12
VPL7F-8
VPL7F-12
1
Pump
PL15A
PL15A
PL15A
PL15A
PL15A
PL15A
PL15A
PL15A
2
Pressure Gauge
M519C
M519C
M519C
M519C
M519C
M519C
M519C
M519C
3
Belt Guard (Standard)
CC1016892
CC1016892
CC1016892
CC1016892
CC1016892
CC1016892
CC106893
CC106893
3
Belt Guard (With ACAC)
CC1016898
CC1016898
CC1016898
CC1016898
CC1016898
CC1016898
CC106899
4
Drain Valve
VP1022988
VP1022988
VP1022988
VP1022988
VP1022988
VP1022988
5
Check Valve
P05822A
P05822A
P05822A
P05822A
P05822A
P05822A
CC106899
VP102298
8
P05822A
6
Bucket High Drain
7
Pressure
Switch
Z1541
Z1541
Z1541
Z1541
Z1541
Z1541
Z1541
Z1541
175 PSIG
P14202A
P14202A
P14202A
P14202A
P14202A
P14202A
P14202A
P14202A
250 PSIG
P07422A
P07422A
P07422A
P07422A
P07422A
P07422A
P07422A
P07422A
175 PSIG
M2843
M2843
M2843
M2843
M2843
M2843
M2843
M2843
250 PSIG
M2845
M2845
M2845
M2845
M2845
M2845
M2845
M2845
3HP
3HP
3HP
5HP
5HP
5HP
7.5HP
7.5HP
175 PSIG
P01161D
P01217D
P02212D
P01161D
P01217D
P02212D
P01217D
P02212D
250 PSIG
P10715D
P07781D
P07782D
P10715D
P07781D
P07782D
P07781D
P07782D
M3590
M3590
CQM3756
M3590
M3590
CQM3756
M3590
CQM3756
9
Pressure
Relief
Valve
Motor
10
Tank
11
Isolation Valve
8
12
Pulley
175 PSIG
M4309D
12
13
Pulley
VP1022988
P05822A
M4309D
M4309D
250 PSIG
P13912A
PULLEY
PULLEY
P05607A
P05607A
BUSHING
PULLEY
BUSHING
CC100597
9
PULLEY
PULLEY
M7009D
M7009D
M7009D
P08083A
P08083A
P08083A
PULLEY
PULLEY
CC1005979
P09358A
P09358A
P09358A
P05607A
P05607A
BUSHING
BUSHING
BUSHING
BUSHING
BUSHING
5L650(2)
5L680(2)
5L680(2)
5L680(2)
B68 (2)
B68 (2)
5L650(2)
5L680(2)
5L680(2)
5L680(2)
5L690 (2)
5L690 (2)
P11923A
P11923A
P11923A
175 PSIG
5L650(2)
5L650(2)
250 PSIG
5L650(2)
5L650(2)
Belts
P13912A
21
UNIT REPAIR PARTS ILLUSTRATION
MODELS: BPL-3, BPL-5, & BPL-7F
C355-A
(Ref. Drawing)
REPAIR PARTS LIST
1
2
2
3
4
Pump
Belt Guard (Standard)
Belt Guard (With ACAC)
Base Plate
Motor
5
Pulley
5
Pulley
6
Belts
175 PSIG
250 PSIG
175 PSIG
250 PSIG
BPL-3
PL15A
Z307
CC1016898
P09195C
3 HP
MODEL
BPL-5
PL15A
Z307
CC1016898
P09195C
5 HP
M4309D
M7009D
P11923A
5L650 (2)
5L650 (2)
P08083A
Pulley
P09358A
Bushing
5L680 (2)
5L680 (2)
22
BPL-7F
PL15A
CC1016894
CC1016899
P09195C
7.5 HP
P13912A
Pulley
P5607A
Bushing
CC1005979
Pulley
P5607A
Bushing
B68 (2)
5L690 (2)
UNIT REPAIR PARTS ILLUSTRATION
MODELS: HPL5D-8, HPL5D-12, & HPL7DF-25
C359-A
(Ref. Drawing)
REPAIR PARTS LIST
1
2
3
3
4
4
5
6
7
Pump
Pressure Gauge
Belt Guard (Standard)
Belt Guard (With ACAC)
Belt Guard (Standard)
Belt Guard (With ACAC)
Drain Valve
Check Valve
Bucket High Drain
8
Pressure Switch
9
Pressure Relief Valve
10
Motor
11
Tank
12
Isolation Valve
13
Pulley
175 PSIG
250 PSIG
175 PSIG
250 PSIG
175 PSIG
250 PSIG
175 PSIG
13
Pulley
250 PSIG
14
Belts
175 PSIG
250 PSIG
15
16
Starter
Alternator
HPL5D-8
PL15A
M519C
Z307
CC1016898
CC1016897
CC1016898
VP1022988
P05822A
Z1541
P14202A
P07422A
M2843
M2845
5 HP
P05767D
----------CQM3756
MODEL
HPL5D-12
PL15A
M519C
Z307
CC1016898
CC1016897
CC1016898
VP1022988
P05822A
Z1541
P14202A
P07422A
M2483
M2845
5 HP
P14130D
-----------CQM3756
M7009D (2)
M7009D (2)
P08083A
Pulley (2)
P08083A (2)
P09358A
Bushing (2)
5L680 (4)
5L680 (4)
5L680 (4)
5L680 (4)
CONSULT FACTORY
CONSULT FACTORY
23
HPL7DF-25
PL15A
M519C
CC1016895
CC1016901
CC1016672
CC1016900
VP1022988
P05822A
Z1542
P14202A
P07422A
M2483
M2845
7.5 HP
P05763D
P12209D
CQM3756
P13912A
Pulley (2)
P05607A
Bushing (2)
CC1005979
Pulley (2)
P05607A
Bushing (2)
B68 (4)
5L690 (4)
COMPRESSOR REPAIR PARTS ILLUSTRATION
AIR COOLED AFTERCOOLER
301CAS810-A
(Ref. Drawing)
24
Repair Parts List
Air Cooled Aftercooler
Ref. No.
Ref. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27
28
29
Description
Description
Nipple, Horizontal Units Only
Street Elbow, Horizontal Units Only
Isolators (5hp Units)
Isolators (7.5hp Units)
Screw (5hp Units)
Screw (7.5hp Units)
Compression Elbow
Elbow, Tube
Screw (5HP Units)
Screw (7.5HP Units)
Nut (5HP Units)
Nut (7.5HP Units)
Bracket, Beltguard
Bracket, Beltguard, Lower
Trim, Panel
Belt Guard
Belt Guard, Back
Belt Guard, Back End
Check Valve
Discharge Tube, Upper
Discharge Tube, Lower 30GH
Discharge Tube, Lower 60-80-120GH
Discharge Tube, Lower 250GH
Discharge Tube, Lower 60-80-120GV
Discharge Tube, Basemount
Bracket, ACAC (5hp Units)
Bracket, ACAC (7.5hp Units)
Bracket, ACAC (7.5hp Units)
Bracket, Beltguard, Lower (5hp Units)
Bracket, Beltguard, Lower (7.5hp Units)
Aftercooler
Compression Ferrule
Compression Nut
Compression Fitting
Bracket, Coupling
Screw
Nut
Compression Fitting
25
Part Number
Part Number
M1035B
M1296
M1367
M1367
M1454
M1683
M2288
M2398
M2627
M2627
M3485
M3485
M866
P04147A
P04365A
P04555B
P04556B
P04557A
P05822A
P10143B
P10705B
P10144B
M2474
P10422B
P10143B
P07831B
P11644B
P12857B
M854
P13809A
P14477B
SE542
SE541
M2398
CC1032600
M3471
M3424
M2398
Qty.
1
1
4
8
4
9
2
1
2
4
3
7
1
1
2
1
1
1
1
1
1
1
1.5 FT.
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
COMPRESSOR REPAIR PARTS ILLUSTRATION
PL15A
C311-A
(Ref. Drawing)
Model:
26
Repair Parts List
Compressor Model PL15A
Ref.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Description
Part
Number
Crankcase
Pipe plug
Oil level gauge
Pipe nipple
Pipe cap
O-Ring
Oil screen
Spring
Pipe plug
Crankshaft
Main bearing
Oil seal
Bearing housing gasket set
Bearing housing
Adaptor
Oil pressure gauge
Pipe plug
Hex head cap screw
3/8 x 1/4 NPT 90 compression fitting
Oil pump adaptor ring
Coiled spring pin
Oil pump spring
Oil pump plunger
Oil pump
Oil pump cover gasket
Oil pump cover
Hex head cap screw
Oil filter
Diaphragm
Plunger
Unloader housing
Hex head cap screw
Control valve
1/4 x 1/8" NPT Straight compression fitting
Close pipe nipple
Shuttle valve
Flywheel
Key
Hex head cap screw
Hex nut
Connecting rod assembly (includes items 42, 43 &44)
Bearing insert (sold in pairs)
P07383D
64AA5
RE714
M492
M461
P07428A
P07381B
P07427A
M998B
P11544C
ZNR16
OSN4
Z12115
P11541D
P11513A
2009741
64AC1
M2594
86A86
P10074A
M3426
P10071A
P10072A
P10070A
P11512A
P10957C
M3274
P10066A
P07585A
P07586A
P07386B
M2596
P08691A
M2863
M1012B
P08692A
NR7A
U8
M738
M2955
Z12116
Z3254
27
Qty.
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
4
1
1
2
1
1
1
1
1
4
1
1
1
1
2
1
3
1
1
1
1
1
1
2
2
Repair Parts List
Compressor Model PL15A
Ref.
No.
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
Description
Part Number
Qty.
Piston pin bearing
Connecting rod bolt
Low pressure piston with pin
Piston pin
Piston pin retaining ring
Low pressure piston ring set
High pressure piston with pin
High pressure piston ring set
Cylinder flange gasket
Cylinder
Hex head cap screw
Gasket, Valve, LPIN, R10-30
Intake valve cage
Valve spring
Valve disc
Intake valve seat
Unloader spring
Guide stem
Unloader finger
Locking hex nut
Unloader piston
O-Ring
Low pressure intake manifold
Unloader cylinder
Hex head cap screw
Valve gasket
Discharge valve seat
Valve disc
Valve spring
Discharge valve cage
Valve gasket
Hex head machine screw
Low pressure discharge manifold
Ferrule
Compression nut
Valve gasket
Intake valve cage
Valve spring
Valve disc
Intake valve seat
R1037
M1583
ZR154
R1021
R10102
Z798
ZP02709C
Z797
NR29A
P12237D
M2345
CQP14832A
M2098
RE1458
RE1470
RE1471
P09084A
P09083A
P09085A
P09086A
P09923A
P02547A
P09670C
P02306B
P05005A
P04135A
M2097
RE1061
RE1059
M2099
P04135A
M3220
RE102E
SE542
SE541
P09171A
P14224B
P13866A
P13865A
P14118B
2
4
1
2
4
1
1
1
1
1
6
1
1
1
1
1
1
1
1
1
1
2
1
2
8
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
28
Repair Parts List
Compressor Model PL15A
Ref.
No.
Description
Part Number
Qty.
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
98
99
99
100
101
102
103
104
105
106
107
Gasket, Valve, HPIN, R10-30
Unloader spring
Guide stem
Unloader finger
Locking hex nut
Unloader piston
High pressure intake manifold
Interstage pressure relief valve
Valve gasket
Discharge valve seat
Valve disc
Valve spring
Discharge valve cage
Gasket, Valve, HPEX, R10-30
Hex head machine screw
High pressure discharge manifold (Non-Base Mount Units)
High pressure discharge manifold (Base Mount Units)
Pressure relief valve (175 psi)
Pressure relief valve (250 psi)
Intake filter
Intake filter element
Low pressure intake valve/unloader assembly
Low pressure discharge valve assembly
High pressure intake valve/unloader assembly
High pressure discharge valve assembly
Pipe plug
Unloader cylinder gasket
CQP14870A
P01882A
P09296A
P14119A
P09086A
P09923A
P12304B
CC1009750
P04137A
RE757A
RE1062
RE760
M2100
CQP14869A
M3220
P12303B
M1717
P09704A
P12078A
P04999A
P05050A
Z4877
Z813
Z11938
Z115
64A5
P00746A
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Complete compressor pump gasket set (items 6,13,25, & 51)
Low pressure piston kit (items 45 & 48)
High pressure piston kit (items 49 & 50)
Complete compressor pump ring set (items 48 & 50)
Z9119
Z9101
Z9100
Z799
1
1
1
1
29
COMPRESSOR REPAIR PARTS ILLUSTRATION
Model: PL15A
C312-A
(Ref. Drawing)
Repair Parts List
Models PL15A
Ref. No. Description
1
2
3
4
5
6
7
8
9
10
11
11
11
12
13
14
15
16
Part Number
Control valve tube
Head unloader tube
Shuttle valve tube
Breather tube
3/8 x 1/4" NPT Straight compression fitting
1/4 x 1/4 x 1/8" NPT Tee compression fitting
1/4 x 1/8" NPT 90 Compression fitting
Manifold tube (includes fittings)
Intercooler (includes fittings)
Pilot valve bracket
Pilot valve (140 – 170 psig)
Pilot valve (90 – 120 psig)
Pilot valve (215 – 245 psig)
Hex head cap screw
1/4 x 1/8" NPT straight compression fitting
Pipe bushing
Needle valve
NPT Tee compression fitting
30
P10835A
P10832A
P10836A
P10838A
M2864
M2879
M2868
Z9172
Z9140
M807
M2853
M2854
M2858
M3465
M2863
M947B
P07717A
M2879
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
UNIT HAZARD DECAL LISTING
PAGE DESCRIPTION
30
PART NO.
PRODUCT LIABILITY DECAL SHEET - MASTER
Unit Pressure Setting
NOT USED
DANGER – Breathing Air
DANGER – Drain Tank Daily
WARNING – Pressure/Safety Valve
NOT USED
DANGER – Valve Maintenance
DANGER – High Voltage
WARNING – Hot Surfaces
WARNING – Do Not Remove Fan Guard
NOTICE - Lubricant
NOT USED
DECAL – Synthetic or Food Grade Inserts
NOT USED
DECAL – Pressure Setting: 140-175PSIG
DECAL – Pressure Setting: 215-250PSIG
NOTICE – Read and Retain Manuals
INSTRUCTIONS – Dual Control
DECAL – Rotation Direction
NOT USED
DECAL – Pressure Switch
P10157A
1
2
3
4
5
6
7
8
9
10
11a
11b
12
13
14
14
15
16
17
18
P14667A
PUMP HAZARD DECAL LISTING
PAGE DESCRIPTION
31
PART NO.
PUMP DECAL SHEET – MASTER
NOT USED
NOTICE - Lubricants
DECAL – Rotation Direction
NOTICE – Read and Retain Manuals
DANGER – Breathing Air
DECAL – Made in the United States of America
IMPORTANT NOTICE – Motor Burn-outs
P13805A
A1
A2
B
C
D
E
F
P14677A
31
UNIT HAZARD DECALS
32
PUMP HAZARD DECALS
F
33
RECORD OF MAINTENANCE SERVICE
DAILY
● CHECK OIL LEVEL
● DRAIN MOISTURE FROM TANK
WEEKLY
MONTHLY
EVERY 3 MONTHS
● CLEAN FILTER
● CLEAN COMPRESSOR
● CHECK V-BELTS
● INSPECT AIR SYSTEM
● CHANGE OIL & OIL FILTER
● INSPECT VALVE ASSEMBLIES
● TIGHTEN ALL FASTENERS
● TEST PRESSURE RELIEF VALVE
34
RECORD OF MAINTENANCE SERVICE
DAILY
● CHECK OIL LEVEL
● DRAIN MOISTURE FROM TANK
WEEKLY
MONTHLY
EVERY 3 MONTHS
● CLEAN FILTER
● CLEAN COMPRESSOR
● CHECK V-BELTS
● INSPECT AIR SYSTEM
● CHANGE OIL & OIL FILTER
● INSPECT VALVE ASSEMBLIES
● TIGHTEN ALL FASTENERS
● TEST PRESSURE RELIEF VALVE
35
*F92193PLAVER18*
*F92193PLAVER18*
Champion
1301 North Euclid Avenue
Princeton, Illinois 61356 USA
Phone (815) 875-3321
Fax (815) 872-0421
Copyright © 2009 Gardner Denver, Inc.
Printed in U.S.A.
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
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