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OPERATION/MAINTENANCE MANUAL & PARTS LIST PL Series 2-Stage Pressure Lubricated Air Compressor & Units Featuring the PL70A 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.
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.
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 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...
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.
TWO STAGE AIR COMPRESSORS - MODEL PL70A DIMENSIONS ITEM PL70A Base-Width 12-7/8” Bolt Down-Width 5-11/16” (from center line) Bolt Down to Edge 3/4” Base to Crank Ctr 8-3/16” Overall Width 33” Overall Height 33-9/16” HP Exhaust Opening 1-1/4NPT Bolt Down Hole Dia. 9/16”...
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.
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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.
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.
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OPERATION (CONT’D) Initial Start Up Inspect unit for any visible signs of damage that would have occurred in shipment or during installation. Pull main disconnect switch to unit to assure that no power is coming into the unit. “Lock Out” or “Tag Out”...
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.
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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.
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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.
COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running: Loosen locknut (4) and back off several turns. Do not turn differential pressure adjustment nut (3). 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.
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.
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.
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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.
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UNIT REPAIR PARTS ILLUSTRATION MODELS: HPL20-12, HPL20-25, HPL25-12, HPL25-25, HPL30-12, & HPL30-25 C371-A (Ref. Drawing) REPAIR PARTS LIST MODEL HPL20-12 HPL20-25 HPL25-12 HPL25-25 HPL30-12 HPL30-25 Pump PL70A PL70A PL70A PL70A PL70A PL70A Pressure Gauge M519C M519C M519C M519C M519C M519C Belt Guard Z674 Z674...
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UNIT REPAIR PARTS ILLUSTRATION MODELS: BPL-20, BPL-25, & BPL-30 C372-A (Ref. Drawing) REPAIR PARTS LIST MODEL BPL-20 BPL-25 BPL-30 Pump PL70A PL70A PL70A Belt Guard Z674 Z674 Z674 Base Plate P03538C P03538C P03538C Motor 20 HP 25 HP 30 HP P05634A P09311B P03710A...
COMPRESSOR REPAIR PARTS ILLUSTRATION Model: PL70A C317-A (Ref. Drawing) Repair Parts List Models PL70A Ref. No. Description Part Number Qty. 1/4 x 1/8" NPT 90 Compression fitting M2868 Manifold tube M1510 1/4 x 1/4 x 1/8" NPT Tee compression fitting M2879 Intermediate tube M1512...
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 –...
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 ●...
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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 ●...
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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 ●...
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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...