Table of Contents
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Compressor & Units Featuring the PL30A 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.
HPL10-12 UNIT
Form No. F102193PLA
VER: 01
PL Series 2-Stage Pressure Lubricated Air
C360-A
(Ref. Drawing)
04/23/02
WARNING
OPERATION/MAINTENANCE
MANUAL & PARTS LIST
PL30A PUMP
C328-A
(Ref. Drawing)
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Table of Contents
Related Manuals for Champion PL Series
Summary of Contents for Champion PL Series
- Page 1 OPERATION/MAINTENANCE MANUAL & PARTS LIST PL Series 2-Stage Pressure Lubricated Air Compressor & Units Featuring the PL30A Pump WARNING 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.
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Page 2: Maintain Compressor Reliability And Performance With
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. -
Page 3: Table Of Contents
TABLE OF CONTENTS _______________________________________________________ Subject Page Maintain Compressor Reliability And Performance With ..............2 Explanation Of Safety Instruction Symbols And Decals ............... 4 Safety And Operation Precautions......................5 Introduction ............................6 Warranty..............................6 Dimensions And Specifications......................7 Installation ............................8 & 9 Operation.............................10 &... -
Page 4: Explanation Of Safety Instruction Symbols And Decals
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. -
Page 5: Safety And Operation Precautions
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... -
Page 6: Introduction
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. -
Page 7: Dimensions And Specifications
TWO STAGE AIR COMPRESSORS - MODEL PL30A DIMENSIONS ITEM PL30A Base-Width 11-3/8” Bolt Down-Width 4-13/16” Bolt Down to Edge 3/4” Base to Crank Ctr 7” Overall Width 26-1/2” Overall Height 23-9/16” Exhaust Opening 3/4 NPT Bolt Down Hole Dia. 17/32” Base-Depth 10-7/16”... -
Page 8: Installation
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. - Page 9 INSTALLATION (CONT’D) 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.
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Page 10: Operation
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. - Page 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”...
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Page 12: Maintenance
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. - Page 13 EVERY 90 DAYS OR 500 HOURS MAINTENANCE Change crankcase oil and oil filter. Use only Champlub recip lubricant. Check entire system for air leakage around fittings, connections, and gaskets, using soap solution and brush. Tighten nuts and cap screws as required. Check and clean compressor valves as required.
- Page 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 oil pressure reaches normal operation range (between 15 and 30 PSIG) the unloader valve closes and the compressor begins to pump air.
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Page 15: Compressor Pilot Valve Differential Pressure Adjustment
COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running: Loosen locknut (2) and back off several turns. 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. -
Page 16: Compressor Oil Specifications
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 this oil for ambient temperatures above 32°F. -
Page 17: Trouble Shooting Guide
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. - Page 18 Troubleshooting Chart (cont’d) Symptom Possible Cause(s) Corrective Action Low or loss of oil pressure Low crancase level. Check oil level. Add oil if required. Oil pickup screen clogged. Drain oil from crankcase. Remove oil pickup screen and clean. Reinstall screen and all clean oil to crankcase.
- Page 19 UNIT REPAIR PARTS ILLUSTRATION MODELS: HPL7-8, HPL7-12, HPL10-8, HPL10-12, HPL15F-12, & HPL15F-25 C-363-A (Ref. Drawing) REPAIR PARTS LIST MODEL HPL7-8 HPL7-12 HPL10-8 HPL10-12 HPL15F-12 HPL15F-25 Pump PL30A PL30A PL30A PL30A PL30A PL30A Pressure Gauge M519C M519C M519C M519C M519C M519C Belt Guard Z650 Z650...
- Page 20 UNIT REPAIR PARTS ILLUSTRATION MODELS: VPL7- 8, VPL7-12, VPL10-8, & VPL10-12 C-362A (Ref. Drawing) REPAIR PARTS LIST MODEL VPL7-8 VPL7-12 VPL10-8 VPL10-12 Pump PL30A PL30A PL30A PL30A Pressure Gauge M519C M519C M519C M519C Belt Guard Z650 Z650 Z650 Z650 Drain Valve M2684 M2684 M2684...
- Page 21 UNIT REPAIR PARTS ILLUSTRATION MODELS: BPL-7, BPL-10, & BPL-15F C-361-A (Ref. Drawing) REPAIR PARTS LIST MODEL BPL-7 BPL-10 BPL-15F Pump PL30A PL30A PL30A Belt Guard Z650 Z650 Z650 Base Plate P03970C P03970C P03970C Motor 7.5 HP 10 HP 15 HP P10718A Pulley Pulley...
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Page 22: Unit Repair Parts List
UNIT REPAIR PARTS ILLUSTRATION MODELS: HPL7D-12, HPL7D-25, HPL10D-25, & HPL15DF-25 C364-A (Ref. Drawing) REPAIR PARTS LIST MODEL HPL7D-12 HPL7D-25 HPL10D-25 HPL15DF-25 Pump PL30A PL30A PL30A PL30A Pressure Gauge M519C M519C M519C M519C Belt Guard Z650 Z650 Z650 Z650 Belt Guard Z1445 Z1445 Z1445... - Page 23 C313-A (Ref. Drawing)
- Page 24 Repair Parts List Compressor Pump Model PL30A Ref. Part Description Qty. Number Crankcase P07382D 1/4" Pipe plug M2326 Oil level gauge RE714 3/8 x 4" Pipe nipple M492 3/8" Pipe cap M461 O-Ring P07428A Oil screen P07381B Spring P07427A 1/2" Pipe plug M998B 3/4"...
- Page 25 Repair Parts List Compressor Pump Model PL30A Ref. Part Description Qty. Number Valve gasket P04134A Intake valve cage M2098 Valve spring RE1458 Valve disc RE1470 Intake valve seat RE1471A Unloader spring P09084A Guide stem P09083A Unloader finger P09085A Locking hex nut P09086A Unloader piston P09923A...
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Page 26: Compressor Repair Parts List
COMPRESSOR REPAIR PARTS ILLUSTRATION Model: PL30A C314-A (Ref. Drawing) Repair Parts List Models PL30A Ref. No. Description Part Number Qty. Discharge tube (includes fittings) ZP08132B Intercooler (includes fittings) Z9141 Intercooler (includes fittings) Z9142 Discharge tube (includes fittings) ZM2474-8 3/4 x 3/4" NPT Compression fitting M2867 3/4"Pipe tube M3140... -
Page 27: Unit Hazard Decal Listing
UNIT HAZARD DECAL LISTING PAGE DESCRIPTION PART NO. PRODUCT LIABILITY DECAL SHEET - MASTER P10157A 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 –... -
Page 28: Unit Hazard Decals
UNIT HAZARD DECALS... -
Page 29: Pump Hazard Decals
PUMP HAZARD DECALS... -
Page 30: Record Of Maintenance Service
RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY MONTHLY EVERY 3 MONTHS ● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL & OIL FILTER ● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES ● CHECK V-BELTS ●... - Page 31 RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY MONTHLY EVERY 3 MONTHS ● CLEAN FILTER ● INSPECT AIR SYSTEM ● CHANGE OIL & OIL FILTER ● CLEAN COMPRESSOR ● INSPECT VALVE ASSEMBLIES ● CHECK V-BELTS ●...
- Page 32 Phone (815) 875-3321 Fax (815) 872-0421 E-mail: champion@championpneumatic.com Copyright 8 2002 Gardner Denver, Inc. Plants in Princeton, IL, and Manteca, CA Printed in U.S.A. Due to Champion=s continuing product development program, specifications and materials are subject to change without notice or obligation...