Compressed Air Advisors Champion PL Series User manual

OPERATION/MAINTENANCE
MANUAL & PARTS LIST
PL Series 2-Stage Pressure Lubricated Air
Compressor & Units Featuring the PL15A 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.
VPL5-6 UNIT PL15A PUMP
Form No. F92193PLA VER: 01 04/23/02
C326-
A
(Ref. Drawing)
C354-
A
(Ref. Drawing)

2
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: ([phone]
Fax: [phone]
E-Mail: Champion@Chamion pneumatic.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.

3
TABLE OF CONTENTS
_______________________________________________________
Subject Page
Maintain Compressor Reliability .................................................................................................................. 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 & 11
Maintenance................................................................................................................................. 12, 13 & 14
Compressor Pilot Valve Differential Pressure Adjustment.......................................................................... 15
Compressor Oil Specifications .................................................................................................................... 16
Torque Valves ............................................................................................................................................. 16
Trouble Shooting Guide ..................................................................................................................... 17 & 18
Unit Repair Parts List ......................................................................................................................19 thru 22
Compressor Repair Parts List .........................................................................................................23 thru 27
Unit Hazard Decal Listing............................................................................................................................ 28
Unit Hazard Decals ..................................................................................................................................... 29
Pump Hazard Decals .................................................................................................................................. 30
Record Of Maintenance Service ................................................................................................................. 31

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.
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 injuries, 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.
Non-approved uses will also void the warranty.
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.
All requests for information, service, spare parts or Maintenance Manual should include machine
serial number and be directed to:

5
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. Read all instructions completely before operating air compressor or unit.
2. 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).
3. 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.
4. 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.
5. Make certain that the power source conforms to the requirements of your equipment.
6. 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.
7. Do not attempt to remove any compressor parts without first relieving the entire system of
pressure.
8. Do not attempt to service any part while machine is in an operational mode.
9. Do not operate the compressor at pressures in excess of its rating.
10. Do not operate compressor at speeds in excess of its rating.
11. Periodically check all safety devices for proper operation. Do not change pressure setting or
restrict operation 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 without guards, shields and screens in place.
16. 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.
17. Do not operate compressor in areas where there is a possibility of ingesting flammable or toxic
fumes.
18. 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.
19. Inspect unit daily to observe and correct any unsafe operating conditions found.
20. Do not "play around" with compressed air, nor direct air stream at body, because this can cause
injuries.
21. Compressed air from this machine absolutely must not be used for food processing or breathing
air without adequate downstream filters, purifiers and controls.
22. 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.
23. Check hoses for weak or worn condition before each use and make certain that all connections
are secure.
24. Always wear safety glasses when using a compressed air blow gun.
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.

6
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 - 100% Allowance, Parts and Labor
Second Year - 90% Allowance, Parts and Labor
Third Year - 80% Allowance, Parts and Labor
Fourth Year - 70% Allowance, Parts and Labor
Fifth Year - 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

7
TWO STAGE AIR COMPRESSORS - MODEL PL15A
DIMENSIONS
ITEM PL15A
A
B
C
D
E
F
I
J
K
L
M
N
O
P
Q
R
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 175 3 440 12.8 505 6700 4.31
PL15A 175 5 710 20.7 800 12
,
000 7.00
PL15A 175 7.5 1035 30.2 1195 16
,
800 9.75
PL15A 250 3 380 11.0 454 6
,
700 375
PL15A 250 5 640 18.5 740 12
,
000 6.75
PL15A 250 7.5 940 27.4 1087 16
,
800 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
C-327-
A
(Ref. Drawing)

8
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.
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.
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
3 PHASE
1 PHASE
MOTOR
HP 200/208V 230V 460V 575V 115V 208V 230V
3
14
14
14
14
8
10
10
5
10(8)
12(8)
14(12)
14
--
8(6)
8(6)
7½
8(6)
10(6)
14(10)
14(10)
-- --
6(4)
Values in ( ) for Duplex Unit w/one incoming power line to both motors.

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.
Figure 1-1 Simplex Wiring Diagram
Figure 1-2 Duplex Wiring Diagram
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.
B1164-
A
(Ref. Drawing)
B1165-
A
(Ref. Drawing)

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 25’ 50’ 100’ 200’ 300’
PL15A 3/4” (1”) 3/4” (1”) 3/4” (1”) 1” (1-1/4”) 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.
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 cut-
out 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. Inspect unit for any visible signs of damage that would have occurred in shipment or during
installation.
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 cand 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:
Remove bolts and guard to access compressor drive.
Loosen mounting hardware which secures motor to base. Slide motor within slots of baseplate to
desired position.
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.
Check the alignment of pulleys. Adjust if necessary.
Tighten mounting hardware to secure motor on base.
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 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
longer 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.
NOTE: If after the compressor shuts off air escapes from the hydraulic unloader for more than a
couple of seconds, it indicates the tank check valve is leaking. See "Check Valve" below.
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 (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).
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 this oil for ambient temperatures
above 32°F.
CHAMPLUB synthetic is a premium grade diester based synthetic lubricant providing excellent
performance in both high and low temperature applications.
CAUTION
Do not mix oil types, weights or brands.
If changing to the synthetic lubricant, the following steps must be completed.
1. Changing lubricant in a compressor that has not been run.
•Thoroughly drain existing oil from crankcase.
•Fill crankcase with a partial carge, 3/4 quart, of synthetic lubricant.
•Run compressor for 5 minutes.
•Stop compressor and thoroughly drain the synthetic lubricant.
•Fill crankcase with a full charge.
2. Changing lubricant in a compressor that has been running in the field.
•Thoroughly drain existing oil from crankcase.
•Fill crankcase with a full charge of synthetic lubricant.
•Run compressor for 200 hours.
•Stop compressor and thoroughly drain the synthetic lubricant.
•Add a full charge of synthetic lubricant.
•Compressor now ready to run for extended period before next lubricant change.
LUBRICANT
CHAMPLUB
DESCRIPTION PART NUMBER
1 – Quart Case (12/case) P12612A
1 – Gallon Case (4/case) P12613A
5 – Gallon Pail P12614A
55 – Gallon Drum P12615A
CHAMPLUB SYNTHETIC
DESCRIPTION PART
NUMBER
1 – Quart Case (12/case) P13179A
1 – Gallon Case (4/case) P13180A
5 – Gallon Pail P11506A
55 – Gallon Drum P13181A
TORQUE VALVES
SPECIFIC APPLICATION FASTENER SIZE & THREAD TORQUE INCH-POUNDS
BEARING HOUSING BOLT 3/8 – 16 400
CYLINDER FLANGE BOLT 7/16 – 20 400
CONNECTING ROD BOLT 5-16 – 18 230
MANIFOLD BOLT 3/8 – 16 200
FLYWHEEL BOLT 1/2 – 13 600

17
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 Possible Cause(s) Corrective Action
Motor will not start. 1. Main switch and fuses open.
2. Starter heater coils open.
3. Starter tripped
4. Defective pressure switch-
contacts will not close
5. Low voltage.
1. Check all fuses and switches. Check
for loose or faulty wires.
2. Check overload relay in starter.
Reset starter.
3. Reset starter. If starter trips
repeatedly, have electrical system
inspected by an electrician.
4. Repair or replace pressure switch.
Warning – Relieve tank pressure
before servicing.
5. Check with voltmeter. Be sure
voltage corresponds to unit
specifications.
Starter trips repeatedly. 1. Improperly adjusted pressure switch.
2. Faulty check valve.
3. Incorrect fuse size or magnetic starter
heaters.
4. Low voltage.
5. Defective motor.
1. Adjust or replace.
Warning – Relieve tank pressure
before servicing.
2. Clean or replace
Warning – Relieve tank pressure
before servicing.
3. Be sure that fuses and heaters are
properly rated.
4. Check with voltmeter. Be sure
voltage corresponds to unit
specifications.
5. Replace motor.
Tank pressure builds up slowly. 1. Air leaks.
2. Dirty air filter.
3. Defective compressor valves
1. Tighten fittings.
2. Clean or replace.
3. Install new valve plate assembly.
Tank pressure builds up quickly. 1. Excessive water in tank. 1. Drain tank.
Discharge pressure relief valve pops
off while compressor is running.
1. Wrong pressure switch setting.
2. Defective ASME relief valve.
1. Adjust to correct setting.
2. Replace valve.
Warning – Relieve tank pressure
before servicing.
Compressor will not unload 1. Wrong pilot valve setting.
2. Defective pilot valve.
3. Lack of air to pilot valve..
1. Adjust to correct stting
2. Replace pilot valve.
3. Open needle valve to pilot valve.
Excessive belt wear. 1. Pulley out of alignment.
2. Belts too tight or too loose.
1. Realign motor pulley.
2. Adjust belt tension.
Compressor runs hot. 1. Improper flywheel rotation
2. Defective compressor valves.
3. Dirty air filter.
4. Dirty cylinder and/or intercooler.
1. Check for correct rotation.
(Counter clockwise when viewed
from drive side.
2. Install new valve plate assembly.
3. Clean or replace.
4. Clean cylinder fins and/or intercooler.
Interstage pressure relief valve pops off. 1. Defective compressor valves. 1. Install new valve plate assembly.
Excessive oil consumption. 1. Dirty air filter.
2. Wrong oil viscosity.
3. Oil leaks.
4. Worn piston rings.
5. Scored cylinder
1. Clean or replace.
2. Refill with proper viscosity oil.
3. Tighten bolts. Replace gaskets.
4. Replace rings.
5. Replace cylinder.

18
Troubleshooting Chart (cont’d)
Symptom Possible Cause(s) Corrective Action
Low or loss of oil pressure 1. Low crancase level.
2. Oil pickup screen clogged.
3. Faulty oil pump..
1. Check oil level. Add oil if required.
2. Drain oil from crankcase.
Remove oil pickup screen and clean.
Reinstall screen and all clean oil to
crankcase.
3. Replace oil pump.
System does not alternate
(Duplex units only)
1. Starter tripped.
2. Loose wiring in alternator.
3. Defective alternator.
4. Defective
motor.
1. Reset starter. If starter trips
repeatedly, have electrical system
inspected by an electrician.
2. Check and tighten all wiring
connections.
3. Replace
alternator.
4. Replace motor.

19
UNIT REPAIR PARTS ILLUSTRATION
MODELS: HPL3-6, HPL3-8, HPL3-12, HPL5-6, HPL5-8, HPL5-12, HPL7F-8 &
HPL7-12
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 Z307 Z307 Z307 Z307 Z307 Z307 Z307 Z307
4 Drain Valve M2684 M2684 M2684 M2684 M2684 M2684 M2684 M2684
5 Check Valve P05822A P05822A P05822A P05822A P05822A P05822A P05822A P05822A
6 Bucket High Drain Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541
175 PSIG P14202A P14202A P14202A P14202A P14202A P14202A P14202A P14202A
7 Pressure
Switch
250 PSIG P07422A P07422A P07422A P07422A P07422A P07422A P07422A P07422A
175 PSIG M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843
8
Pressure
Relief
Valve 250 PSIG M2845 M2845 M2845 M2845 M2845 M2845 M2845 M2845
9 Motor 3HP 3HP 3HP 5HP 5HP 5HP 7.5HP 7.5HP
175 PSIG P01136D P01164D P01596D P01136D P01164D P01596D P01164D P01596D
10 Tank
250 PSIG P09374D P07436D P07434D P09374D P07436D P07434D P07436D P07434D
11 Isolation Valve M3590 M3590 M2686 M3590 M3590 M3590 M3590 M3590
P07981A P07981A
PULLEY PULLEY
P05607A P05607A
12 Pulley 175 PSIG
M4309D M4309D M4309D M7009D M7009D M7009D BUSHING BUSHING
P11657A P11657A
PULLEY PULLEY
P05607A P05607A
12 Pulley 250 PSIG
P11923A P11923A P11923A P08083A P08083A P08083A BUSHING BUSHING
13 Belts 5L650(2) 5L650(2) 5L650(2) 5L680(2) 5L680(2) 5L680(2) B68 (2) B68 (2)
C-358-A
(Ref. Drawing)

20
UNIT REPAIR PARTS ILLUSTRATION
MODELS: VPL3-6, VPL3-8, VPL3-12, VPL5-6, VPL5-8, VPL5-12, VPL7F-8, &
VPL7F-12
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 Z307 Z307 Z307 Z307 Z307 Z307 Z307 Z307
4 Drain Valve M2684 M2684 M2684 M2684 M2684 M2684 M2684 M2684
5 Check Valve P05822A P05822A P05822A P05822A P05822A P05822A P05822A P05822A
6 Bucket High Drain Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541 Z1541
175 PSIG P14202A P14202A P14202A P14202A P14202A P14202A P14202A P14202A
7 Switch
250 PSIG P07422A P07422A P07422A P07422A P07422A P07422A P07422A P07422A
175 PSIG M2843 M2843 M2843 M2843 M2843 M2843 M2843 M2843
8
Pressure
Relief
Valve 250 PSIG M2845 M2845 M2845 M2845 M2845 M2845 M2845 M2845
9 Motor 3HP 3HP 3HP 5HP 5HP 5HP 7.5HP 7.5HP
175 PSIG P01161D P01217D P02212D P01161D P01217D P02212D P01217D P02212D
10 Tank
250 PSIG P10715D P07781D P07782D P10715D P07781D P07782D P07781D P07782D
11 Isolation Valve M3590 M3590 M2686 M3590 M3590 M2686 M3590 M3590
P07981A P07981A
PULLEY PULLEY
P05607A P05607A
12 Pulley 175 PSIG
M4309D M4309D M4309D M7009D M7009D M7009D
BUSHING BUSHING
P11657A P11657A
PULLEY PULLEY
P05607A P05607A
12 Pulley 250 PSIG
P11923A P11923A P11923A P08083A P08083A P08083A BUSHING BUSHING
13 Belts 5L650(2) 5L650(2) 5L650(2) 5L680(2) 5L680(2) 5L680(2) B68 (2) B68 (2)
C-357A
(Ref. Drawing)