DIESEL POWERED

SCREW AIR COMPRESSORS

PG 450-150 \ PG 350 - 200 \ PG 400 - 175

PG 600 -100 \ PG 380 - 200 \ PG 400 - 150
PG 400 - 175 AC
WITH 6BTA ENGINE

OPERATION AND MAINTENANCE MANUAL

PARTS MANUAL
©
Elgi Equipments Limited
Coimbatore, TN - 641 005

Part / Document No. : 039400014_R05

Replaces Earlier

Doc. No. : Nil

Date : Nil

Contact Info :
Elgi Equipments Limited,
Trichy Road, Singanallur
Coimbatore, TN - 641 005, India
Tel : 91 - 422 2589555
Fax : 91 - 422 2573697 (Domestic Business)
Fax : 91 - 422 2589401 (International Business)
E-mail : [email protected], [email protected], www.elgi.com
Domestic Toll free No. : 1800 425 3544
Customer Care No. :0091 422 2589242, 243, 244 , 245
Machine Identification and
Sale Record
Owner’s Name : ______________________________

Address : ______________________________

Model : ______________________________

FAB No. : ______________________________

Year of Manufacture : ______________________________

Engine : ___________________________hp

Capacity : ________________________m3/ min

Rated Pressure : _________________________bar

Date of Delivery : ______________________________

Date of Commissioning : ______________________________

Dealer’s Name/Code : ______________________________

Dealer’s signature and stamp

Note: The warranty on this compressor is valid only if all the details
above are filled in and the dealer stamps and signs this page

Note: To avail warranty benefits, please fill above information and send
it to customer care mail ID for registration purpose.
Email ID [email protected]

iii
Owner Possession Information

Warranty Book Serial No. : ______________________________

Customer Code : ______________________________

Customer Name : ______________________________

Customer Address : ______________________________

Contact Data

Phone : ______________________________

Mobile GSM : ______________________________

Mobile CDMA : ______________________________

Fax : ______________________________

E-mail : ______________________________

Compressor Type : ______________________________

Compressor Model : ______________________________

Fabrication No. : ______________________________

Invoice No. : ______________________________

Date of Delivery : ______________________________

Place of Purchase : ______________________________

Airend Type : ______________________________

Airend Serial No. : ______________________________

Engine Model : ______________________________

Engine Serial No. : ______________________________

iv
Message from the Managing Director

Dear Elgi Customer,

It gives me great pleasure to welcome you to the family of users of the Global
Series Diesel Powered Screw Air compressors from Elgi, among the most
sophisticated rotary screw air compressors available in the world today.

Elgi has designed your Global Series Compressor to be reliable, safe, easy to
maintain and friendly to use in meeting your compressed air requirements. This
user manual will enable you to use the Global Series Compressor optimally.
Please familiarize yourself with all the information it contains.

I look forward to your continued satisfaction as a Global user. Elgi is honoured

to be your choice for all your compressed air needs.

Yours sincerely

(signed)

v
About ELGI

Elgi, established in 1960, designs and manufactures a wide range of

compressors. The company has gained its reputation for design and manufacture
of screw compressors through strategic partnerships and continuous research
and development.

Screw compressor elements are manufactured in-house using state-of-the-art

machining centres for rotor grinding and machining castings of various sizes.
Elgi’s own eta-V profile rotors ensure energy-efficient compressed air supply
for all demanding applications. Elgi is one of the few companies capable of
manufacturing wide range of airends and compressor packages in the world.
Elgi’s patent portfolio is a testament to the company’s continuous research and
innovation capability.

Elgi has modern manufacturing facilities in equipped with advanced high precision
grinding machines, turning centres and CNC horizontal and vertical machining
centres. Screw airends are manufactured with the latest rotor grinding technology,
coupled with measurement technology to maintain precise manufacturing
tolerances. Elgi's manufacturing plants are both ISO and EOHS certified.Elgi
serves the world market place. Over two million compressors are powering
business in 63 countries worldwide. The company offers a strong sales and
service network with a well-knit distribution network of dealers and distributors
worldwide. Elgi has its own manufacturing facilities in China, France, India and
Italy. Additionally, Elgi has warehouse operations to stock units and parts
inAustralia, Brazil, UAE and USA.

vi
Introduction

ELGI EQUIPMENTS LIMITED is a leading Indian manufacturer of Rotary

Screw Air Compressors. Elgi Rotary Screw Air Compressors are widely used
in India and other parts of the world. The equipment is known for their reliability,
maintenance, friendliness and safety. Every Screw Type Air Compressor is
designed keeping in mind three key quality considerations viz.

l Energy Efficiency

l Air Quality

l Maintenance

We are confident; the equipment you have purchased will give you satisfactory
service for its life.

We thank you for giving us an opportunity to serve you with our Compressor.
Please check and ensure OPERATION AND MAINTENANCE MANUAL, PARTS
MANUAL and ENGINE MANUAL are received along with the compressor. If
not, contact your local Dealer / Elgi equipments Ltd.

This Operation and Maintenance Manual has been specially designed keeping
you in mind, so that you can get the most out of Elgi Compressor. Before you
start using your compressor, do go through this manual thoroughly. It contains
vital information on operations and useful tips that will keep your compressor
running as good as new, year after year.

All information, illustrations and specifications in this manual are based on the
latest product development available at the time of supply. We reserve the
right to make changes in the product at any time without notice. We assure
you of the best service in maintaining uptime of the compressor through prompt
service and supply of spare parts as per your requirements.

This manual has been prepared with utmost care to help the user to understand
various systems involved in the compressor thoroughly through detailed
descriptions, working conditions and illustrations. This manual must be made
available to the compressor operating personnel at all times.

Please read the instructions very carefully, right to the end, as the operating
life and reliability of the compressor depends to a large extent on correct
operation and maintenance.

1.0
General Information

Your Global Series Compressor belongs to a family of rotary screw compressors

from Elgi. Overall, the features of your Global Series Compressor translate to
convenience for you. The compressor has only two moving parts—the rotors—
which do not touch each other but are separated by a thin film of oil, so that
there is no wear. This also means that the reliability of the compressor is
unsurpassed.

The screw compressor technology ensures that there is no reduction in output

capacity even after many years of operation. It involves a continuous flow of
air through helical cavities in the screw, and so the compressed air delivery is
pulsation free. The design of the Global Series compressor gives you a compact
and self-contained compressor. Because it has no reciprocating parts, it runs
quietly and free of vibrations. The discharge temperature of the coolant oil is
low, less than 90OC, and therefore carbonized oil is not formed in the
compressor.

Please read the instructions in this manual carefully and follow them at all
times. The operating life and reliability of the compressor depend to a large
extent on correct operation and maintenance.

When calling your Elgi branch office, dealer or service centre regarding your
compressor, keep at hand the details present on the name plate of the
compressor and entered in the inside front cover of this manual.

When ordering spare parts, refer to the list provided in this manual and identify
the part number. Specify the part number and quantity in addition to the name
plate details.

2.0
 ELGI’s Customer Care System
(CCS)
Elgi provides high-quality customer care and after-sales support through the
CCS, a computerized system developed in-house. The CCS aims to minimize
the time taken to resolve complaints.
Service Requests/Complaints
At the heart of the CCS is the toll-free telephone number for domestic
1800-425-3544 at the centralized customer care centre at Coimbatore.
Customers can register their service requirements or complaints with
coordinators here.
A unique tracking number is generated for each call logged by the CCS. The
customer is sent an automatic e-mail acknowledgement with the tracking
number and details of the call for reference.
A service engineer is assigned to the call, and the date and time of the
engineer's visit are communicated to the customer by e-mail. Every
requirement or complaint must be resolved and closed in the CCS within a
specified time limit, failing which the call is brought automatically to the notice
of the manager higher in the hierarchy, up to the level of the Managing Director.
Thus the CCS ensures that not only are customer complaints logged, they
are also attended on time every time.
Enquiries
A number of calls received by the CCS relate to customers' queries regarding
products and spare parts. The details are noted, and basic information on
product specifications and usage are provided. The caller is informed whom
to contact for further discussions. The enquiry is passed on to a salesperson
at the Head Office or the appropriate branch for follow-up.
The CCS Database
The CCS also creates a database of customers, adding every new customer
calling and thereby building a large pool of installation details. These details
are used to provide value-added services to improve customer satisfaction
with Elgi products.
CCS-Working Hours
Customers can now use the CCS from 08:30 to 21:30 IST six days a week
(Monday to Saturday). Elgi has received suggestions that the service be
extended to Sundays.
Multi-lingual Capability
The coordinators at the CCS are multi-lingual. They can handle calls in all the
major regional languages of India.

3.0
Coverage
The toll-free number of the CCS is accessible in domestic from the following
areas:
Southern Region: Tamilnadu, Karnataka, Kerala, Pondicherry, Andhra
Pradesh, Andaman & Nicobar Islands
Western Region: Maharashtra, Gujarat, Madhya Pradesh, Goa,
Lakshadweep islands
Eastern Region: Orissa, Chattisgarh, Jharkhand, West Bengal, Bihar and
the North-Eastern states
Northern Region: Rajasthan, Uttar Pradesh, Delhi, Haryana, Punjab,
Uttaranchal, Himachal and Jammu & Kashmir.
Other Contact Numbers for Domestic Customers
The CCS can also be availed through the following numbers:
Telephone : 0091 - 4222589206
- 4222589241
- 4222589242
- 4222589243
- 4222589244
- 4222589245
- 4222589246
- 4223254247
Fax : 0422 - 2589240 - Domestic business
0422 - 2589401 - International business
For International Customers
Please send the following details through mail, enable us to take
immediate action

Name of the Customer

Compressor Model

Fab Number

Contact Person Name

Phone Number

Nature of Complaint

Hour Meter Reading
You may use the CCS by sending e-mail to: [email protected]

3.1
Commissioning Process

Customer Satisfaction Survey

If you have used the CCS, you may be contacted and your feedback sought on
the after-sales support received by you. Your response helps Elgi to improve
this service.

Before the new Global Series compressor is operated for the first time, it needs
to be installed at your site according to Elgi’s specifications. Elgi’s commissioning
engineer carries out a series of checks on the machine and the systems to
which it is connected to ensure that it is in a condition to function safely and as
desired. The engineer will then describe to the operator of your compressor how
the equipment is to be operated and maintained. This procedure is referred to
as the commissioning process.

The commissioning of your compressor ensures that it is installed safely: the

general operating conditions of the equipment such as the cleanliness of the
atmosphere, temperature and ventilation are checked. Technical details
relating to your system such as particulars of your electrical installation are
noted. The operator of your compressor is familiarized with all aspects of both
its normal running and dealing with unusual situations. The commissioning
process provides to Elgi data that will help understand your requirements better.

Please make preparations for commissioning yourGlobal Series compressor

according to the instructions provided in the Installation section of this manual.
Ensure that the location chosen meets the requirements of accessibility,
ventilation and safety.

Upon completion of the commissioning process, the commissioning engineer

will fill in a document known as the commissioning report. Please verify the
information filled in and attest the certificate of completion of commissioning.
The Elgi commissioning engineer will also sign the report. Kindly hand over the
commissioning report to the commissioning engineer. Please fill in also the
warranty card that comes along with the compressor and hand it over to the
engineer. The engineer will send the report and the card to Elgi’s Service
Department — Compressor Division, Head Office.

4.0
Using this operation and
Maintenance Manual
This operation and maintenance manual has been specially designed keeping
you in mind so that you can get the most out of your Elgi Global Series
Compressor. Before you start using your compressor, do go through this manual
thoroughly. It contains vital information on operation as well as useful tips that
will help you keep your compressor running as good as new year after year.

The manual has been prepared with utmost care to help you understand the
various systems of the compressor thoroughly through descriptions,
information and illustrations.

All information, illustrations and specifications in this manual are based on

the latest product information at the time of preparation of the manual. We
reserve the right to make changes in the product at any time without notice.

The manual must be available at all times to the personnel operating the
compressor.

5.0
Definitions and symbols

NOTE:

A Note clarifies procedures or conditions which may otherwise be

misinterpreted or overlooked. A Note may also be used to clarify apparently
contradictory or confusing situations.

CAUTION:

A Caution is provided to draw attention to a procedure which, if not carried

out done correctly, can lead to equipment damage.

WARNING:

A Warning calls attention to dangerous or hazardous conditions inherent to

the operation, cleaning and maintenance of the equipment which may result
in personal injury or death of the operator or other persons.

SYMBOLS:

Never operate the Never breathe in

machine without compressed air
protective equipment

Never operate the Warning:

unit with open doors
Hot surface
or loose

Warning: Change the

Danger of Electric oil filter cartridge after
Shock approximately

Lifting Warning: Pressurized

part or system

Warning: Check the

connecting terminals
and retighten if required

6.0
List of Contents

Section 1 USER INFORMATION Page No.

General 7.0
Warranty Information 7.0
Before commissioning 7.5
Compressor Location 7.7
Section 2 SAFETY 8.0
Section 3 DO’S AND DON’T’S 9.0
Section 4 SALIENT FEATURES & SPECIFICATIONS 10.0
Salient Features 10.0
Technical Specifications 10.2
Section 5 INSTALLATION 11.0
General 11.0
Installation Requirements 11.0
Connection of the Compressor Air Supply 11.1
Electrical Connection 11.1
Preshipment procedurefor compressor stored 11.2
for more than 6 months
Section 6 COMMISSIONING
Points to Be Observed Before Initial Start 12.0
Preservation for Whole Package 12.2

6.1
 List of Contents

Preservation Procedure for Airend Kept Idle 12.2

for Six Months and Above
Preservation Procedure for Engine Kept Idle for 12.3
Six Months and Above—Before Commissioning
Compressor Commissioning Checklist 12.4
Checklist for Engine Preparation Before 12.6
Commissioning
Starting Procedure 12.7
Checklist for Engine Running Performance 12.8
Compressor Daily Maintenance Checklist 12.9
Section 7 WORKING PRINCIPLE 13.0
Section 8 SYSTEM OPERATION 14.0
Section 9 FUNCTIONS OF VARIOUS SYSTEMS 15.0
Air Inlet System 15.0
Discharge System 15.2
Cooling and Lubrication System 15.4
Capacity Control System 15.11
Trolley System 15.17
Canopy System 15.19
Engine System 15.21
Lubrication Oil 15.23
Section 10 SAFETY SYSTEM AND
INTERLOCKING DEVICES 16.0
Safety Devices 16.0
Interlocking Devices 16.1

6.2
List of Contents

Section 11 ELECTRICAL SYSTEM AND

CONTROL ELEMENTS 17.0
System Components and Description 17.1
Instrument Panel 17.1
Electrical Diagram 17.2
Purpose of Controls 17.8
Section 12 MAINTENANCE 18.0
General 18.0
Daily Operation 18.0
Maintenance Checklist-After 500 Hours of Running 18.1
Maintenance Checklist-After 1500 Hours of Running 18.2
Maintenance Checklist-After 3000 Hours of Running 18.2
Maintenance Checklist-After 5000 Hours of Running 18.3
Oil Filter 18.4
Separator Element 18.7
Air Inlet Filter Cleaning Procedure 18.9
Drive Coupling Assembling and
Dismantling Procedure 18.11
Control System Adjustment 18.13
Operating Adjustment 18.13
Butterfly Valve Adjustment 18.13
Pressure Regulator Valve Adjustment 18.14
Idle Speed Adjustment 18.15

6.3
 List of Contents

Minimum Pressure Valve 18.17

Oil Stop Valve 18.19
Blow Down Valve 18.21
Discharge Check Valve 18.23
Pressure Regulator valve 18.25
Single Acting Actuator 18.27
Airend Maintenance 18.28
Oil Cooler and Radiator Maintenance 18.28
Battery Maintenance 18.28
Flushing the Compressor 18.30
Section 13 TROUBLE SHOOTING 19.0
Conversion Tables 20.0
Torque Values 21.0
Disclaimers 22.0
Business Reply Card 23.0
Feedback Form 24.0

6.4
User Information

General

ENSURE THAT THE COMPRESSOR IS LIFTED USING THE LIFTING EYE

PROVIDED ON THE LIFTING BAIL ONLY.
Ensure that this operation manual is made available at all times to the
personnel operating the compressor.

Please read the instructions carefully and strictly adhere to them as the
operating life and the reliability of the compressor depend to a large extent
on correct operation and maintenance.

When communicating with an Elgi dealer/service centre/branch office regarding

your compressor, ensure that all the details on the name plate (format shown
below) are given. The name plate is fitted on the front of the compressor base
frame. For ordering spare parts, refer to the Recommended Spare Parts section
and provide the part number along with the required quantity in addition to the
name plate data of the compressor.
Warranty Information
The Company recommends that every Elgi compressor owner familiarize himself
or herself with this warranty document. The warranty is explicitly/implicitly
subjected to certain conditions. These are summarized here for the benefit of
the owners.

The warranty is subjected to fulfilment inter alia of the following obligations by

the purchaser/owner of the compressor.

Proper installation of the compressor. This is the sole responsibility of
the purchaser.

Normal use and preventive maintenance as recommended by the
compressor owner’s operation manual supplied along with each
compressor.

Warranty will be applicable subject to use of Elgi genuine parts.

Warranty as expressed/implied shall stand to exist only when the
equipment is registered with dealer/Elgi plant.

In case any defects are noticed, it would be a worthwhile effort on the
owner’s part to satisfy himself or herself in the first instance that the
defect could be reasonably deemed to be of workmanship or material
and that the compressor was never subjected to conditions in respect
of which the warranty has been expressly negated.
7.0
User Information
Warranty Information

Any attempt to tamper with, or interchange any parts between,

compressors shall void the warranty. The company has a record of
each compressor and parts utilized thereon duly coded.

Warranty claims related to the engine would be made directly to the
engine manufacturer at their respective regional centres only. This is
in line with an agreement arrived between Elgi and the engine
manufacturer. Refer to the engine manufacturer’s warranty conditions
(given along with the sale documents) as per international warranty terms
and conditions.

Engines, oil coolers, radiators, separator elements, batteries etc., not
manufactured by us are usually warranted by the respective
manufacturers. This shall however be applicable as expressed/implied
for warranty as per manufacturer’s guidelines of maintenance/operation/
usage.

The maintenance of the equipment has to be strictly logged in the log
book and preserved, and the log book shall be shown at any time when
demanded by an Elgi authorized representative.

To analyse the cause for compressor failure, or for any major failure, the
compressor package is to be brought to the place of service to be
rendered, i.e., factory or regional service centre or dealer’s or agent’s
premises.

Used products, and products not assembled by Elgi, are sold as is with
no representation or warranty, and all warranties of quality, written, oral
or implied, other than may be expressly agreed to by Elgi, in writing,
including without limitation, warranties of merchantability or fitness, are
hereby disclaimed.

In no event shall Elgi be liable for special, indirect, incidental or
consequential damages however arising, whether in warrant, strict
liability, contract, tort, negligence or otherwise, including but not limited
to loss of profits of revenue, loss of total or partial use of the products,
facilities of services, downtime costs or claims of purchaser for such or
other damages whether on account of products furnished hereunder
or delays in delivery there of will not be Elgi’s liability.

7.1
User Information
Warranty Information

. Elgi’s liability on any claim, whether in warranty, strict liability, contract,

tort, negligence or otherwise, for any loss or damage arising out of,
connected with or resulting from this warranty or the performance or
breach thereof, or from the design, manufacture, sale, delivery, resale,
repair, replacement, installation, technical direction of installation,
inspection, serving, operation or use of any product covered by or
furnished under this warranty shall in no case exceed the purchase
price allowable to the product or part thereof which gives rise to the
claim.

Notice of claims against Elgi hereunder for any reason, including breach
of warranty, must be made to Elgi in writing within forty-eight (48) hours
of discovery to afford Elgi the opportunity to make a prompt investigation
of the surrounding facts and mitigate any damage which might ensue,
should it be determined to be Elgi’s responsibility. Failure to give such
notice to Elgi shall constitute a waiver by purchaser of any right later to
assert such a claim.
• Any cause of action against Elgi arising out of or relating to the warranty
or the performance hereof shall expire unless brought within two (2) years
of the time of actual thereof. Please refer Warranty / Service Log Book
for detailed warranty instructions for major components.
• We provide warranty for the following equipment for a period of THIRTY
MONTHS from the date of supply or twelve months from the date of
commissioning whichever is earlier against defective material and bad
workmanship and is valid only when the product is used in accordance
with the manufacturer’s instructions as stated in the Operation &
Maintenance Manual.
1. Warranty Does Not Apply To

. Any compressor that shall have been subject to overspeeding, misuse,
negligence or accident.

If the compressor is not commissioned by Elgi/ authorised person and
duly not recorded in the Customer Maintenance Log Sheet.

Failures in any way resulting from use of parts not manufactured or
approved by us.

Normal maintenance services including but, not limited to compressor
tune up and the repair or replacement of filters, compressor and other
normal maintenance spares.
7.2
User Information
Warranty Information

The months/hours criteria would work on "whichever Is earlier" system

from the date of invoicing the unit to the original user.

The Commissioning of compressor shall be done only by Elgi/Authorised
persons, after due verification of sal.e documents of compressor and
duly recorded in the log book

Wherever Hour Meter reading is not available for warranty claims

determination, computatio of total hour worked would be based on an
average working of 10 hours per day from the date of invoice. In case,
exclusion of downtime on account of major breakdown is required,
necessary documentary proof and log book would be verified for the
downtime claimed

Warranty claims must be supported by purchase vouchers for spares

like Air filters/ Oil filters, compressor oil etc, procured through Elgi outlet.
This should correspond to the recommendation of the manufacturer in
terms of quantity, interval of change and source of purchase and proper
recording to be maintained.

In respect of units working away from place of sale, they should receive
necessary service & spares on chargeable basis, from the Authorised
dealers, which is proximate to the working site of the unit. Warranty
claim should be filed with the branch who made the sale along with
purchase vouchers, service report from Authorised dealers which
rendered service and the failed components should be sent to the
M/s. Elgi Equipments Limited, Tennampalayam, Avinashi Road, Arasur
Road, Coimbatore - 641 407 within a period of 15 days from the date of
service report. Any warranty claim made beyond this stipulated time,
would not be entertained. The statutory levies so incurred during part
replacement shall not be refunded when considered for warranty.

We make no warranty as to normal wear and tear, nor do we agree to be

liable for loss of time to the used while the compressor or other equipment
is out of commission, nor for any labour or other expense, damage or
loss occasioned, or claimed to be occasioned by such defective parts.

7.3
User Information
Warranty Information

Any claim or obligation in connection with the sale of our compressor

shall be subject to the jurisdiction of the courts in Coimbatore.

The Company make no warranties expressed or implied relating to the
sale of Elgi's genuine replacement parts.

The Companies warranty practice with respect to allowances made for
material, labour or miscellaneous expenses associated with the repair
of a failure involving genuine Elgi's replacement parts is beyond the
Company's legal obligation.

The Elgi Compressor Unit should be handled and used strictly in
accordance with the manufacturers Manual and Instructions, subject to
which condition alone.

7.4
User Information

Before Commissioning (For skid Model)

Lift the compressor using the lifting bail.

Prior to lifting, inspect the lifting bail and points of attachment for cracked
welds and for cracked, bent, corroded or otherwise degraded members
and for loose bolts and nuts.

Make sure the lifting hook has a functional safety latch, or equivalent,
and is fully engaged and latched on the bail.

Use guide ropes or equivalent to prevent twisting or swinging of the machine
once it has been lifted clear of the ground.

Do not attempt to lift in high winds.

Keep all personnel out from under and away from the compressor when
it is suspended.

Lift the compressor no higher than necessary.

Keep the lift operator in constant attendance whenever the compressor
is suspended.

7.5
User Information

PG 450-150 (TROLLEY)

7.6
User Information

Nomenclature of Models
PG 450 - 150 Portable Global, Diesel driven Trolley model
EXAMPLE:
In PG 450-150
PG – Portable Global
450– FAD in cfm (350 Psig)
150– Pressure value in psig (10.5 bar)

Compressor Location

Please observe the valid accident prevention regulations when installing this
screw compressor.

Install the compressor with adequate accessibility to ensure obstruction-free

operation and maintenance.

The area around the compressor should be clean, dry, cool and free of dust.
Excessively warm intake air affects the compressed air output. The ambient
temperature should not drop below -5°C.

When the ambient temperature is below -5°C, the compressor should not be
operated. For assistance/clarifications on cold start kits and other
arrangements, please contact Elgi India.

7.7
Safety

Elgi designs and manufactures its products for smooth and safe operation.
However, the responsibility for safe operation rests with those who use and
maintain these products. The following safety precautions and devices are
offered as a guide and accessories, respectively. These when followed will
minimize the accidents and failures through out the useful life of the equipment.

Only those who have been trained and delegated to do so and who have read
and understood this operation and maintenance manual should operate the air
compressor. Failure to follow the instructions, procedures and safety precautions
given in the manual may increase the possibility of accidents and failures.

Refer to the operation and maintenance manual of the engine and follow the
instructions as given by the engine manufacturer.

Never start an air compressor unless it is safe to do so. Do not attempt

to operate an air compressor with a known unsafe condition. Tag the
air compressor and render it inoperative by disconnecting power supply
so that others who may not know of the unsafe condition will not attempt
to operate it until the condition is corrected.

This Elgi screw compressor is not explosive-proof and is not to be operated

in explosive areas.

Do not modify the compressor except with written approval from the
factory.

Please verify that the exhaust line rain cap/flap is closed properly after
shutting down the compressor. It is the responsibility of the customer
to avoid rain water entry into the engine.

Follow the safety instructions

8.0
Safety

Pressure Release

. Manually pop up the pressure relief valve when the

compressor is operating, at least weekly, to make sure
the pressure relief valve is not blocked, closed,
obstructed or otherwise inoperative.

Manually pop up the pressure relief valve when the compressor is

operating, at least weekly, to make sure the pressure relief valve is not
blocked, closed, obstructed or otherwise inoperative.

Do not use tools that are rated below the maximum rating of this
compressor. Select tools, air hoses, pipes, valves, filters and other
fittings accordingly. Do not exceed the manufacturers’ rated safe
operating pressure for these items.

Secure all hose connections by wire, chain or other suitable retaining

devices to prevent tools or hose ends from being accidentally
disconnected.

Open the oil fill cap only when the compressor is not running and is not
pressurized. Shut down the compressor and bleed the receiver tank to
zero internal pressure before removing the cap.

Vent all internal pressure prior to opening any line, fitting, hose, valve,
drain plug, connection or other component, such as filters.

Keep personnel out of line with and away from the discharge end of
hoses or tools or other points of compressed air discharge.

Do not use air at a pressure higher than 2.5 kgf/cm2 for any cleaning
purposes.

Do not engage in horseplay with air hoses as death or serious injury may
result.

Do not remove the radiator pressure cap until the coolant temperature is
below its boiling point. Loosen the cap slowly to relieve any excess
pressure and make sure that the coolant is not boiling before removing
the cap completely.

8.1
Safety

After stopping the engine, confirm that the pressure gauge indicates
0 bar and before starting repair and maintenance. Residual air under
pressure will blow off and severely injure the operator.

Under any circumstance, do not open the oil fill cap of the separator
receiver tank while running or immediately after stopping operation. It
is very dangerous because the oil filler could be blown off and
high-temperature compressed air and oil could jet out from the filler port
and cause serious injury.

When you refill the separator receiver tank with compressor oil, stop the
engine and make sure that the pressure gauge indicates 0 bar and that
there is no residual pressure in it, and then gradually loosen the oil filler
cap for refilling oil.

Do not connect the compressor air line to any air receiver directly without
proper grouting and foundation of air receiver. Any hose line needs to
be secured by wires/chain or other suitable retaining devices to pressur
e tools and hose ends from being accidently disconnected.

Fire and Explosion

Clean up spills of lubricant or other combustible
substances immediately if spills occur.

Shut off the air compressor and allow it to cool. Keep

sparks, flames and other sources of ignition away
and do not permit smoking in the vicinity when
checking or adding oil/fuel.

Do not use flammable solvents for cleaning purposes.

Keep electrical wiring and other terminals in good condition. Replace any
wiring that has cracked, cut, abraded or otherwise degraded insulation;
keep all terminals clean and tight.

8.2
Safety

Keep grounded conductive objects such as tools away from exposed

live electrical parts such as terminals to avoid arcing, which might serve
as a source of ignition.

Keep oily rags, trash, dry leaves, litter or other combustibles out of and
away from the compressor.

Do not operate the compressor without a proper flow of cooling air/cooling

water or with an inadequate flow of lubricant or with a degraded lubricant.

Do not attempt to operate the compressor in any class of hazardous

environment unless the compressor has been specially designed and
manufactured for explosive applications.

Disconnect the grounded (negative) battery connection prior to attempting

to any repairs or cleaning inside the compressor enclosure. Tag the battery
connection cable so that others will not accidentally reconnect it.

Switch off the battery charger before making or breaking connections to

the battery.

Keep flames away from the battery because the battery may generate
hydrogen gas and may explode.

Under any circumstance, do not bring lit cigarettes or matches near such
oils as engine oil and compressor oil.

Replace damaged fuel tanks or lines immediately

rather than attempting to weld or otherwise repair
them. Do not store or attempt to operate the
compressor with any known leaks in the fuel
system.

Such parts as mufflers and exhaust pipes can be extremely hot. Remove
twigs, dried leaves, dried grass, waste paper, etc., from the exhaust
outlet of the muffler.

8.3
Safety

Be sure to perform periodical checks of the compressor oil and oil

separator. Neglecting checks could cause overheating of the oil,
resulting in a fire.

Open all the access doors and ventilate the enclosure prior to attempting
to start the engine.

Have fire extinguishers near the unit, ready for emergency situations.

Battery Safety

Never wash the battery with pressurized water.

Never top up with acid/mineral water/tap water/stream water.

Never apply grease on terminals/cable clamps.

Never remove electrolyte, and never overfill the battery.

Never hammer down the clamps on the terminals.

Never operate the vehicle or charge the battery if the electrolyte

temperature exceeds 60°C.

Never short the battery terminals directly with a cable.

Never do any welding work while charging.

Never allow the batteries to run the vehicle with the specific gravity below
1.19.

Never operate vehicles with batteries of two different specific gravity

values.

Never run vehicles with the vent plugs open.

Never recharge the battery without topping up to the maximum level.

Do not connect any other power connections for local lighting/rig lighting
or any other purpose from this battery connection.

8.4
Safety

Moving Parts
Decals are fitted on the compressor to identify
movingrotating parts.

The compressor is designed for running with the

enclosure doors closed. Ensure that no loose parts
are kept inside and that all doors are closed before
starting the compressor.

Keep hands, arms and other parts of the body as

well as clothing away from couplings, fans and other
moving parts during any checking/testing.

Do not attempt to operate the compressor with the

fan, coupling or other guards removed.

DANGER

Death or serious injury may result from inhaling compressed air

without using proper safety equipment.

Wear snug-fitting clothing and confine long hair when

working around the compressor, especially when hot
or moving parts are exposed.

Keep access doors, if any, closed except when

making repairs or adjustments.

Make sure all personnel are out of and/or clear of the

compressor prior to attempting to start or operate it.

8.5
Safety

Disconnect and lock out all power at source and verify

at the compressor that the circuits are
de-energized to minimize the possibility of an
accidental start-up or operation, prior to attempting
repairs or adjustments. This is especially important
when the compressor is remotely controlled.

Keep hands, feet, floors, controls and walking

surfaces clean and free of fluid, water or other liquids
to minimize the possibility of slips and falls.

Make adjustments only when the engine is shut off.

Keep hands away from rotating parts or belts. If hands

are caught they can be seriously injured.

Hot Surfaces

Decals are fitted on the exposed hot surfaces of the

compressor.

Avoid bodily contact with hot oil, hot coolant and hot
surfaces.

Keep all parts of the body away from all points of air
discharge.

Wear personal protective equipment including gloves

and head coverings when working in, on or around
the compressor.

Keep a first-aid kit handy. Seek medical assistance

promptly in case of injury. Do not ignore small cuts
and burns as they may lead to infections.

8.6
Safety

Under any circumstances, do not open the radiator cap while the machine
is running or immediately after stopping operation. High-temperature steam
jets out when this is done, and this could cause scalding.

After stopping the engine, wait for 10 to 20 minutes until the engine oil
cools down. Then check the level of the engine oil, or refill or drain the
oil. Engine oil is very hot and highly pressurized during or just after
operation. Hot oil could blow out of the tank and can cause scalding.

Toxic and Irritating Substances

Do not use air from this compressor for respiration

(breathing).

Exhaust gas from the engine is poisonous and could

cause death when inhaled. Avoid using the machine
in an insufficiently ventilated building or tunnel.

Oils, coolants and lubricants used in this compressor

are typical of the industry. Care should be taken to
avoid accidental ingestion and/or skin contact. In
the event of ingestion, seek medical treatment
promptly. Wash with soap and water in the event of
skin contact.

Never blow compressor air directly towards people.

Scattered impurities, dust and foreign objects in the
compressed air may cause skin and eyes to be
seriously injured.

When the machine has to be unavoidably temporarily

operated with its port open, be sure to mount a silencer
to reduce the noise, and wear protective items such
as ear plugs to prevent damage to hearing.

DANGER

Death or serious injury may result from inhaling compressed air

without using proper safety equipment.

8.7
Safety

Electrical Shock

Keep all parts of the body and any hand-held tools or other conductive
objects away from exposed live parts of the electrical system. Maintain
a dry footing, stand on insulating surfaces and do not contact any other
portions of the compressor when making adjustments or repairs to
exposed live parts of the electrical system. Make all such adjustments
or repairs with one hand only so as to minimize a current path through
the heart.

Attempt repairs only in clean, dry and well-lit and ventilated areas.

Keep the towing vehicle or equipment carrier, compressor, hoses, tools

and all personnel at least 10 feet from power lines and buried cables.

Disconnect, lock out and tag all the power lines prior to attempting repairs
or adjustments to the machinery and prior to handling any ungrounded
conductors.

Lifting

The compressor is provided with a 1
lifting bail (“2”). Ensure that the
compressor is lifted using the lifting 2
provided. Use slings of adequate
4
capacity to lift the compressor more 3
than 3 metres above the ground
level or to transport the compressor
using a helicopter.

Prior to lifting, inspect the lifting bail and points of attachment for cracked
welds and for cracked or bent or corroded or otherwise degraded
members and for loose bolts or nuts.

Make sure that the entire lifting, rigging and supporting structure has
been inspected, is in good condition and has a rated capacity of at
least the net weight of the compressor plus an additional 10% allowance
for the weight of mud or stored tools and equipment. Weigh the
compressor if you are not sure of the total weight.

8.8
Safety

Make sure the lifting hook (“1”) has a functional safety latch or equivalent
and is fully engaged and latched on the lifting bail.

Use guide ropes or equivalent materials (“3”) to prevent twisting or swinging

of the machine once it has been lifted clear of f the ground.

Do not attempt to lift in high winds.

Keep all personnel away from below the compressor when it is suspended.

Do not lift the compressor higher than necessary.

Keep the lift operator in constant attendance when the compressor is

suspended.

Set the compressor down only on level surfaces capable of supporting

at least its net weight plus an additional 10% allowance for the weight
of mud or stored tools and other equipment.

8.9
Safety

Towing the Trolley

A) Preparation

Inspect the air compressor ball hitch, pintle eye or other coupling device,
drawbars and chains if provided, and the towing vehicle coupling device
for defects such as excessive wear or corrosion, cracks, deformed or
degraded members and loose nuts, bolts and other fasteners.

Manoeuvre in a manner that will not exceed the freedom of motion of the
compressor’s drawbar and coupling device in or on the towing vehicle’s
coupling device and adjacent structure, whether towing forwards or
backwards, regardless of the terrain being traversed.

Back the towing vehicle to the compressor trolley and position it in

preparation for coupling the compressor.

Make sure that all access doors and tool box covers are closed and
latched. If the compressor is large enough to hold a man, ensure that
there is no one inside before latching the doors.

Make sure that the parking brakes in towing vehicles are set, or that their
wheels are choked or blocked, or that they are otherwise restrained from
moving. Then release the compressor parking brakes, if these are
provided.

Test the operation of a running brake wherever provided before attempting

to tow the compressor at the permissible speed.

8.10
Safety

B) Towing

When towing the unit, make
sure that there is no person or
obstacle at both the front and
the rear and under the unit.

Observe all traffic laws,

including those specifying the
minimum speed.

Tow at an appropriate speed

as listed below, or slower,
under ideal conditions.

Safe speed limits:

– 30 kmph
Speed variations are allowed according to road conditions.

Remember that the weight of a portable air compressor may approach

or exceed the weight of the towing vehicle. Maintain an increased
stopping distance accordingly.

Avoid grades in excess of 15° (27%).

Avoid potholes, rocks and other obstructions and soft shoulders or

unstable terrain.

Do not permit personnel to ride in or on the compressor.

Make sure prior to packing that the area behind and under the
compressor is clear of all personnel and obstructions.

Do not permit personnel to stand or ride on the drawbar or to stand or

walk between the compressor and the towing vehicle.

8.11
Safety

C) Parking or Locating Compressor

Park or locate the compressor on a levelled
area, if possible. If not, park or locate the
compressor across the gradient so that the
compressor does not tend to roll downhill. Do
not park or locate the compressor on a land
gradient exceeding 15° (27%).

Make sure that the compressor is parked or located on a firm surface that
can support its weight.

Park compressors such that the wind tends to carry the exhaust away
from personnel and away from the compressor air inlet openings and
where the compressor will not be exposed to excessive dust from the
work site.

If chains are provided, unhook and remove them from the points of chain
attachment on the towing vehicle; then hook the chains to the ball on the
drawbar or wrap chains around the drawbar and hook them to themselves
to keep the chains off the ground so that rusting is not accelerated.

If a front screw lock is provided, lower it and/or any rear stabilizer legs.
Make sure that the surface they contact has the load-bearing capability
to support the weight of the compressor.

Keep feet clear of the drawbar at all times to avoid crushing accidents in
case it should slip from your hands or otherwise fall to the ground.

Move the towing vehicle clear of the parked compressor and erect hazard
indicators, barricades and/or flares (if at night) if the compressor
is parked on or adjacent to public roads.

While skid-mounted portable air compressors are not towed in the usual sense
of the word, many of these recommendations are directly applicable to them
as well.

8.12
Safety

Entrapment

Make sure all personnel are out of the compressor before
closing and latching enclosure doors.

If the compressor is large enough to hold a man, and if

it is necessary to enter it to perform service or
adjustments, inform other personnel before doing so,
or else secure the access door in the open position to
avoid the possibility of others closing and latching the
door with personnel inside.

Jump-Starting

Observe all the safety precautions mentioned elsewhere in this manual.

Batteries may contain hydrogen gas, which is flammable and explosive.

Keep flames, sparks and other sources of ignition away.

Batteries contain acid, which is corrosive. Do not allow battery acid to

contact eyes, skin, fabrics or painted surfaces as serious personal injury
or property damage could result. Flush any contacted areas thoroughly
with water immediately. Wear an acid-resistant apron and face shield
when attempting to jump-start the compressor.

Remove all vent caps from the battery or batteries in the compressor. Do
not permit dirt or foreign matter to enter the open cells.

Check the fluid level. If it is low, bring it to the required level before
attempting to jump-start.

Do not attempt to jump-start if the fluid is frozen or slushy. Bring batteries

up to at least 40°F (5°C) before attempting to jump-start.

Cover open cells of oil compressor batteries with clean, damp cloths
before attempting to jump-start.

Attempt to jump-start only with a vehicle with a negative ground electrical

system with the same voltage and that is equipped with a battery or
batteries of comparative size or larger than that supplied with the
compressor. Do not attempt to jump-start using motor generator sets,
welders or other sources of DC power as serious damage may result.

8.13
Safety

Bring the starting vehicle alongside the compressor; do not permit metal-
to-metal contact between the compressor and the starting vehicle.

Set the parking brakes of both the compressor (if provided) and the starting
vehicle on or otherwise block both sides of all wheels.

Place the starting vehicle in neutral or park, turn off all non-essential
electrical loads and start the engine.

Use only jumper cables that are clean, in good condition and are heavy
enough to handle the starting current.

Avoid accidental contact between the jumper cable terminal clips or

clamps and any metallic portion of either the compressor or the starting
vehicle to minimize the possibility of uncontrolled arcing which might
serve as a source of ignition.

Positive battery terminals are usually identified by a plug (+) sign on the
terminal and the letters POS adjacent to the terminal. Negative battery
terminals are usually identified by the letters NEG adjacent to the terminal.

Check your connections. Do not attempt to start a 24 V compressor with

one 12 V battery in the starting vehicle.

Start the compressor in accordance with the normal procedure. Avoid

cranking for more than 5 seconds continuously.

Remove and carefully dispose of the damp clothes as they may be

contaminated with acid. Replace the oil vent caps.

Service Line Hose Connection

Do not connect a high-pressure air service line with a hose and air
receiverarrangement without proper mounting of the air receiver and hose
line.

8.14
Do’s and Don’t ’s

Do’s

Read the manual in detail and follow the instructions.

Clean the air compressor package regularly.

Keep the air filter clean.

Use only genuine Elgi spares.

Use only clean and recommended lubricants.

Maintain the correct oil level.

Use proper tools.

Attend immediately to anything unusual relating to the air compressor.

Maintain a log book to monitor the operation of the compressor.

Attend o repairs/service with qualified technicians only.

Please check that the exhaust line flap is closed properly after the
compressor is shut down.

Don’t’s

Neglect routine attention.

Allow any leakage in the system.

Keep any tools or loose items on the compressor/other modules.

Meddle with any adjustments or settings.

Use cleaning agents when changing oil.

Do any repair work while the unit is running.

Overload the compressor for a long period, even though it is of continuous

rating, as we recommend intermittent use only.

9.0
Salient Features and Specifications

Salient Features

Less Maintenance

A screw compressor has only two moving parts-the rotors-which do not touch
each other as they are kept apart by means of a thin film of oil and hence there
is not wear and tear. There are no reciprocating parts such as pistons, piston
rings and connecting rods and no suction or discharge valves to be maintained.

Maximum Reliability

With only two rotors, moving at a conservative speed, screw compressors

provide a level of reliability never before attained in the history of the compressor
industry.

Low Discharge Temperature

The heat of compression is taken away from the point of origin to the cooler by
the injected oil, and hence the discharge temperature does not exceed 90OC.
No carbonized oil is therefore formed in the compressor and in the system.

Small Package

Because of the unique way in which the screw compresses the air, a complete
air package is provided with modest overall dimensions.

Low Noise and Free of Vibrations

There are no reciprocating masses. There are only rotating parts which are
dynamically balanced.

Long Life

Since there is no metallic contact between the rotors and the housing, and they
are flooded with oil, no wear or reduction in output capacity/performance occurs
even after many years of operation.

10.0
Salient Features and Specifications

No Loss in Capacity

There is no wear in the solid steel screws. Thus there is no loss in performance
due to wear. The compressor provides the same air flow, no matter what its age
is.

Pulsation-Free Flow

The continuous flow of air through the helical cavities in the screw and the
continuous compression ensure pulsation-free compressed air delivery.

Air Quality

The unique tangential air-oil separation system of the compressor ensures

efficient separation of oil particles with a minimal pressure drop from the
compressed air-oil mixture delivered at the compression end. The tangential
system ensures a consistent quality of air during normal running and unloading
cycles.

Low Operating Cost

The operating cost of a screw compressor is generally less than those of other
conventional machines.

10.1
Specification Sheet
MODEL: PG 450-150, PG 350-200, PG 400-175

No. Description Unit PG 450-150 PG 350-200 PG 400-175

01 Free air delivery cfm 450 350 400

m3 /min 12.7 9.91 11.32

02 Working pressure kgf/cm 2 10.34 12.07 13.79

psi 150 200 175

03 Engine make CIL CIL CIL

04 Engine model 6 BTA 5.9-C 6 BTA 5.9-C 6 BTA 5.9-C

05 Max. operating speed rpm 2100 2100 2100

06 Min. operating speed rpm 1250 1250 1250

07 Engine power output hp 169 169 169

08 Engine lube oil capacity litres 16.3 16.3 16.3

09 Engine cooling water capacity litres 10.4 10.4 10.4

10 Battery Quantity. No 2 2 2

11 Battery capacity Ah 120 120 120

12 Flywheel housing SAE #3 SAE #3 SAE #3

13 Oil fill capacity (First fill) litres 27 27 27

14 Air outlet port size Inches 1½ - 1 No, 1½ - 1 No, 1½ - 1 No,

& Qty ¾” - 5 Nos ¾” - 5 Nos ¾” - 5 Nos

15 Net Weight Kgs 2110 2110 2110

16 Reference Standard for ISO 1217:1996 ISO 1217:1996 ISO 1217:1996

FAD and SFC Annex D Annex D Annex D
17 Skid or without under mm 3075 x1340x 3075x1340x 3075x1340x
carriage 1810 (±50) 1810 (±50) 1810 (±50)
18 With under carriage mm 3970 x1860x 3970x1860x 3970x1860x
2165 (±50) 2165 (±50) 2165 (±50)

10.2
Specification Sheet
MODEL: PG 400-175 AC

No. Description Unit PG 400-175 AC

01 Free air delivery cfm 400

m3 /min 11.32

02 Working pressure kgf/cm 2 12.07

psi 175

03 Engine make CIL

04 Engine model 6 BTA 5.9-C

05 Max. operating speed rpm 2100

06 Min. operating speed rpm 1250

07 Engine power output hp 169

08 Engine lube oil capacity litres 16.3

09 Engine cooling water capacity litres 10.4

10 Battery Quantity. No 2

11 Battery capacity Ah 120

12 Flywheel housing SAE #3

13 Oil fill capacity (First fill) litres 27

14 Air outlet port size Inches 1½ - 1 No,

& Qty ¾” - 5 Nos

15 Net Weight Kgs 2110

16 Reference Standard for ISO 1217:1996

FAD and SFC Annex D
17 Skid or without under mm 3075x1340x
carriage 1810 (±50)
18 With under carriage mm 3970x1860x
2165 (±50)

10.3
Specification Sheet
MODEL: PG 380-200, PG 400-150, PG 600-100

No. Description Unit PG 380-200 PG 400-150 PG 600-100

01 Free air delivery cfm 380 400 600

m3 /min 10.8 11.3 17

02 Working pressure kgf/cm 2 13.79 10.34 6.89

psi 200 150 100

03 Engine make CIL CIL CIL

04 Engine model 6 BTA 5.9-C 6 BTA 5.9-C 6 BTA 5.9-C

05 Max. operating speed rpm 2100 2100 2100

06 Min. operating speed rpm 1250 1250 1250

07 Engine power output hp 169 169 169

08 Engine lube oil capacity litres 16.3 16.3 16.3

09 Engine cooling water capacity litres 10.4 10.4 10.4

10 Battery Quantity. No 2 2 2

11 Battery capacity Ah 120 120 120

12 Flywheel housing SAE #3 SAE #3 SAE #3

13 Oil fill capacity (First fill) litres 33 33 33

14 Air outlet port size Inches 1½ - 1 No, 1½ - 1 No, 1½ - 1 No,

& Qty ¾” - 5 Nos ¾” - 5 Nos ¾” - 6 Nos

15 Net Weight Kgs 23400 2340 2340

16 Reference Standard for ISO 1217:1996 ISO 1217:1996 ISO 1217:1996

FAD and SFC Annex D Annex D Annex D
17 Skid or without under mm 3380 x1340x 3380x1340x 3380x1340x
carriage 1810 (±50) 1810 (±50) 1810 (±50)
18 With under carriage mm 4275 x1860x 4275x1860x 4275x1860x
2165 (±50) 2165 (±50) 2165 (±50)

10.4
Installation
Installation

General

The operating instructions given below are for commissioning standard version
air-cooled series compressors without additional equipment. Before
commissioning the equipment, check for visual damage of parts. An electrical
circuit diagram is delivered with every compressor (kept inside the electrical
control panel) for electrical wiring reference.

Every screw compressor is subjected to a test run and set prior to despatch.
Transport damage at a later stage cannot however be excluded. Therefore,
please observe the compressor closely during commissioning and the trial run.

Installation Requirements

While installing the compressors, ensure the following:

The compressor is kept on a levelled surface capable of withstanding

the weight.

Safe operation of the compressor is only ensured if the ambient

temperature remains within the limits.

A forced cool air flow should not be directed towards the compressor.

The compressor is to be located such that hot air from other machines is
not directed towards the compressor.

Keep the compressor under cover to protect it from rain/storms.

Provide a clearance space of 1.5 metres around the compressor.

The battery supplied along with compressor package is not charged. You
need to charge the batteries for 72 hours before commissioning.

NOTE
If you fail to observe the instructions concerning installation
and ventilation, the discharge temperature of the
compressor may increase or decrease excessively and trip
the compressor at high discharge temperature conditions.
The output of the compressor will also be affected.

11.0
Installation

The compressor will not give warnings during short operating times. It will operate
below the dew point, and moisture condensate will mix with the oil. This will
reduce the lubricating qualities of the oil and lead to damage to the compressor.

General Recommendations

The mast or hoses of the mast should not touch the air the intake piping.

The mast or hoses of the mast should not touch the exhaust piping.

The package should operate with all doors closed.

Do not connect a high-pressure air service line with the hose and air
receiver arrangement without mounting the air receiver and hose line
properly.

Connection of the Compressed Air Supply

The unit is set up and ready to operate. Connect the discharge outlet to the pipe
line using a flexible hose or suitable arrangement according to the application.

Electrical Connection

Ensure that only authorized electricians carry out the electrical work.
Study the electrical circuit diagram before starting the work.

The batteries supplied along with the compressor are not charged. Ensure
that the batteries are removed from the unit, prepared suitably and charged.

The electrical connections in the compressor are completed and tested

at the factory before shipment. The wiring circuit diagram is supplied
along with the compressor. Study the wiring diagram before providing
the connection.

Fix the batteries in position (after charging) and secure them. Connect
the cables to the batteries as per the wiring diagram.

Check the correctness of the connections first with a multi-meter and

then by switching on the lamp in the compressor.

Remove the battery connection when the compressor is not ready for
starting. This is to ensure accidental starting by unauthorized personnel/
personnel unaware of the state of the compressor.

11.1
Installation

Pre-shipment procedure for compressor stored for more than six

months
COOLANT SYSTEM

Drain radiator water.

Flush cooling system using air at a pressure of 5 psi.

Block all the openings, if any, on the engine block.

Tell the customer to add anti-freeze agent before starting the engine,
along with the coolant.

The anti-freeze coolant specifications are provided subsequently.

FUEL SYSTEM

Drain all the diesel in inlet and return lines. (In some cases the fuel
leakage line needs to be drained out)

Fuel hose ends to be tightened or blocked with proper arrangement so
that no moisture will enter into the system.

Flush the system by air pressure.

Block the opening in fuel system.

Remove the fuel filter element

LUBE OIL SYSTEM

Drain all the oil from the pan.

Flush the oil system by air pressure.

Block all the openings, if any, in the lube system.

Check the suitability of the oil before starting the engine.
The specifications of the oil to be followed.

Remove the used oil filter element including the bypass and place a new
filter element in it and despatch.

Care is to be taken at the time of commissioning to despatch the unit
with a new filter element. At the time of commissioning, the element has
to be taken out and immersed in oil and refitted so that the engine starts
without any problem. This is applicable for fuel system filters also.

11.2
Commissioning

On receipt of the compressor unit at your warehouse, please open the door and
take the compressor manual bag, which is tied to the lifting bail pillar. In the
compressor manual bag you will find the compressor manual, engine manual,
compressor warranty card, engine warranty card, battery manual & battery
warranty card, test certificate and packing slip.

The compressor door keys and panel keys are tied to the service line ball valve
handle.

Points to be Observed Before Initial Start

Every compressor is test run in the factory and carefully checked before
shipment. The test run confirms that the compressor conforms to the
specifications and runs perfectly. However, regardless of the checks carried
out at the factory, the compressor could be damaged during transport. We
recommend that the compressor be examined for such damage and if any
damage is found that it be reported to the nearest dealer / Elgi Equipments Ltd.

ATTENTION
Important functional components in the compressor (such
! as the minimum pressure valve, pressure relief valve, inlet
valve, regulator, pressure switches and temperature switch)
are adjusted and fitted. Alterations to these components are
not allowed without prior consultation with the manufacturer
/ field service engineer.

ATTENTION
The minimum pressure valve and pressure relief valve are
! spring actuated.

Points to be observed before starting

ATTENTION
If these instructions (WARNING, ATTENTION) are not
! complied with, accidents can occur, causing injury to
persons or damage to equipment

12.0
Commissioning

Operate the compressor with doors kept closed.

The operator is expected to employ safe working conditions and to

follow all prescribed operating and safety regulations while operating
this compressor.

The user of this compressor is responsible for its safe operating

conditions.

Do not operate this compressor under heavy dust conditions-toxic or

inflammable gases could be present.

Do not connect the compressor to a supply voltage other than that

specified in the technical specifications section.

Do not install the compressor in a place subject to freezing temperatures.

The air temperature at the air intake must be above +5°C.

Check and ensure that the oil filter elements are fitted properly.

Open the air outlet line ball valve (provided on the front side of the
compressor) fully before starting the compressor.

12.1
Preservation

Preservation Procedures for Whole Package

Preservation Procedure for Airend Kept Idle for Six Months
and Above

The preservation procedure should be followed if an airend will be idle for
more than six months.

Remove the inlet valve at the suction of the airend.

Pour 4 litres of rust-preventive oil into the suction.

Rotate the input shaft 10 times in the clockwise/anticlockwise direction.

Remove the discharge plug after pouring rust-preventive oil and drain the
rust preventive oil thoroughly.

After draining the rust-preventive oil from the airend, refit the discharge
plug.

Close the suction using the inlet valve.

Carry out this procedure every three months until usage.

12.2
Preservation

Preservation procedure for engine kept idle for six months and
above-before commissioning

Change the engine oil (lube).

Change the lube oil filter.

Change the diesel filter.

Change the corrosion filter.

Change the engine air filter.

Replace the radiator coolant, if required.

Remove the engine turbo oil line hose and lubricate it with engine oil.

Drain the radiator and flush it out.

Inspect the fuel line non-return valve (NRV).

Remove the fuel tank drain the dust.

SINGLE-STAGE AIREND—AXIS MODEL

12.3
Preservation
Compressor Commissioning Checklist

1 Check for the air filter element.

2 Check/ensure that the clamps on the duct are tightened properly.

3 Check/ensure that the mounting bolts of airend & engine are tightened
properly.

4 Check/ensure that the cooler/radiator mounting bolts are tightened

properly.

5 Check/ensure that the air-oil receiver mounting bolts are tightened

properly.

6 Check/ensure that the canopy bolts are tightened properly.

7 Check the condition of the oil filter element.

8 Pour new compressor oil into the air-oil receiver tank. The compressor
oil fill capacity is 27 litres.

9 Check/ensure that the oil lubricating line on the airend is tightened

properly.

10 Check/ensure that the pulse line to the oil stop valve is tightened
properly.

11 Check/ensure that the pulse line to the blow down valve is tightened
properly.

12 Check/ensure that the pulse line to the actuator is tightened properly.

13 Check/ensure that the pulse line to the regulator assembly is tightened

properly.

12.4
Preservation
Compressor Commissioning Checklist

15 Check/ensure that the actuator on the butterfly valve assembly is fitted

properly.

16 Check/ensure that the pulse lines to all the gauges are tightened
properly.

17 Check for any loose connections on the electrical terminals on the

control panel board.

18 Check/ensure that the oil hose is fitted properly.

19 Check/ensure that all the bolts of the trolley, base frame and wheels
are tightened properly.

20 Check whether the towing arrangement and trolley are fitted properly.

21 Check/ensure that there is no damage to the electrical cables to avoid

a short circuit.

22 Check/ensure that all the safety interlock switches are intact, including
the wiring.

23 Check for any loose connections in the electrical terminals on the

tripping switches.

24 Check the compressor exhaust duct flap condition and its closing
and opening positions. This is very important.

25 Check the condition of the door hinges.

26 Check whether the roof light condition is OK or not.

27 Check whether the air suction rubber elbow is tight.

28 Check / ensure battery condition (Voltage)

29 Run the compressor and record the performance parameters

12.5
Preservation
Checklist for Engine Preparation Before Commissioning

1 Fill/check the oil level in the engine using the dipstick provided on the
engine block. If required add oil so that it reaches the necessary level.
Consult with the local Cummins representative for the right grade of
oil.

2 Fill/check the water level in the engine radiator. Check with Cummins
for the appropriate engine coolant.

3 Check/ensure that the coupling bolts are tightened properly.

4 Ensure that the battery is charged for 48 hours before the compressor
is commissioned.

5 Check/ensure that the battery terminals are connected properly.

6 Check the fan belt tension.

7 Check/ensure that the clamps holding the exhaust manifold on the

silencer are tightened properly.

8 Check the engine air filter condition and clamps tightness.

9 Check/ensure that the engine bed mounting bolts are tightened properly.

10 Check/ensure that the engine fan shroud bolts are tightened properly.

11 Check the gap between the engine fan and the shroud gap, and check
its position.

12 Check the engine belt tension and adjust its tightness.

13 Check the engine safety switches and their condition.

14 Check the condition of the radiator and oil cooler AVM.

12.6
Preservation

Starting Procedure

Install the compressor on a surface levelled using a spirit level.

Switch on the power supply to the compressor. The switch is provided

on the instrument panel.

Turn the ignition key and press the override button simultaneously for 5
seconds.

Check that the engine rotates clockwise when viewed from the fan side.

Release the ignition key as soon as the engine fires.

Restart the engine after an interval of 1 minute.

Run the compressor for 1 minute to circulate the compressor oil. Switch
it off.

Note : If the engine does not start within 5 seconds, release the
ignition key and override button.

Five minutes after stopping the compressor, check the oil level in the
receiver tank. After the fumes settled down, the oil level should be up
to the half mark on the glass.

Run the unit for 15 to 20 minutes and check for any leakage.

The oil level of the compressor should be checked after the compressor
is shutdown and, when the compressor and air-oil fumes settled down
completely. The oil level should be half glass visible.

The settings of the pressure regulator, electrical protection devices, etc.,

are set at the factory during the testing before despatch.

The foregoing procedure must be followed during re-installation of the

compressor at a new location.

If the compressor is stored for a longer period before commissioning, contact

the Elgi service engineer for installation and commissioning services.

12.7
Preservation
Checklist for Compressor / Engine Running Performance

1 Check the engine lubrication oil pressure.

2 Check the engine water temperature.

3 Check whether the alternator is charging.

4 Check the RPM meter and its condition.

5 Check the hour meter and confirm that it is working.

6 Check whether the engine exhaust joint leaks.

7 Check the condition of the engine turbo.

8 Check whether there is any leakage in the suction line.

9 Check the tightness of the engine air suction rubber elbow.

10 Check whether the roof light condition is ok or not.

11 Check whether there are any leaks from flanges and joints.

12 Check for oil leakage

13 Check the compressor discharge oil temperature

14 Check the compressor pressure

15 Check the valve functions

12.8
Preservation

Compressor Daily Maintenance Check List

1 Drain moisture/water from the sump before starting the unit.

2 Drain moisture/water from the moisture filter fitted on the control line
during operation.

3 Check and clean the air filter.

4 Check whether the exhaust line flap has been closed properly after
the compressor has been shut down.

5 Check whether the compressor oil level is at the half mark of the
glass before starting the unit.

6 Check the engine oil and radiator water coolant levels.

12.9
Working Principle
Working Principle

WORKING PRINCIPLE OF SCREW AIR COMPRESSOR

13.0
Working Principle

Compression of air is achieved in a rotary screw compressor in the

following manner. Air is admitted at one end of the rotors, where the
matching lobe and flute first mesh as the rotors turn. Continued rotation
brings the line of meshing past the air inlet port, and then the air in the
flute of the female rotor is confined by the lobe of the male rotor and
stator. Compression now occurs as the rotors turn further. The far end
of the compression pocket turns towards the discharge port and air
flows out in the system, as shown in the accompanying figure, which
depicts one lobe meshing with one flute.

The flutes of the female rotor and the lobes of the male rotor correspond,
respectively, to the cylinder and piston of a reciprocating compressor.
Lubricating oil is injected into the compressor unit (here referred to as
the airend), which mixes directly with the air in large quantities as the
rotors turn, compressing the air.

The lubricating oil has four functions.

a) As a coolant it takes away the heat of compression.

b) It seals the leakage paths between the rotors and housing.

c) It acts as a lubricating film between the rotors, allowing one rotor to drive
the other directly without a metal-to-metal contact.

d) It also lubricates the bearings and gears.

13.1
System Operation

WORKING PRINCIPLE OF SCREW AIR COMPRESSOR

14.0
System Operation

The air aspirated through the air filter is compressed in the screw
compressor driven by the diesel engine. The air drawin into the
compressor is throttled by the butterfly valve.

The air–oil mixture is delivered to the receiver tank through the discharge
check valve which acts like a non-return valve.

The oil and air are separated by the tangetial process in tank.

The separated oil is cooled in the oil cooler and is returned to the injection
point through the oil filter. This oil circulation circuit, operated solely by a
pressure differential, does not require a separate oil pump.

A final separation is done using a high-efficiency separator, maintaining

oil carry-over levels consistently below 10 ppm.

The thermal valve provided in the oil circuit ensures the desired discharge
temperature for optimum performance.

Oil collected in the receiver tank is cooled by the oil cooler and returned
back to the airend through the main oil filter and oil stop valve.

Compressed air liberated from the air–oil separator element is delivered

to the service line through the minimum pressure valve.

The minimum pressure valve positioned downstream of the oil separator

maintains a minimum pressure for supply of oil to the compressor unit
for safety.

The engine is throttled by the actuator, which in turn gets the input air
from the receiver tank through the pressure regulator and moisture
separator.

Refer to the schematic diagram provided for various elements used in

the system.

14.1
Functions of various systems

AIR INLET SYSTEM

15.0
Functions of various systems

Air Inlet Systems

The air inlet system comprises a dry-type filter, which filters the inlet air
and prevents foreign particles from entering the airend.

The air inlet valve is of the butterfly type and directly controls the amount
of air entering the airend. The opening or closing of the valve disc
controls the port area in response to the function of a single-acting
spring-loaded actuator which operates in coordination with the control
system. The actuator receives operating pulses from the pressure
regulator valve.

Replace air filter elements when the restriction indicator is red, or every
1000 hours, whichever is earlier.

15.1
Functions of various systems
BLOCK DIAGRAM OF DISCHARGE SYSTEM

DISCHARGE SYSTEM
15.2
Functions of various systems

Discharge System

The screw air compressor discharges a compressed air-oil mixture through
a discharge check valve into the receiver tank.

The discharge check valve prevents the compressed air from returning
to the compression chamber after the unit is shut down.

The compressed air-oil mixture enters the receiver tank tangentially.
Heavier particles are separated and fall to the bottom of the receiver
tank. The separator element at the final stage of air-oil separation is
the vital element for getting clean air at the outlet. The separated oil
collects on the element surface and descends to the bottom of the
separator.

The return valve (or scavenge line) leads from the bottom of the separator
element to the inlet regime of the compressor unit, ensuring that the
separated oil is returned to the compressor by the pressure differential
between the area surrounding the separator element and the compressor
inlet. The nylon tube used in the return line usually checks the oil flow.

The minimum pressure valve at the outlet of the receiver tank ensures a
minimum receiver pressure of 4kgf/cm2 during all conditions for proper
air-oil separation and proper oil circulation to the airend.

A pressure relief valve (located on the wet side of the separator) is set to
open if the receiver tank pressure exceeds the working pressure by 10%.

Oil is to be filled in the receiver tank through the elbow welded on the
tank after removing the plug. An oil sight glass enables the operator to
visually monitor the receiver tank oil level.

Do not remove caps, plugs or other components when the

! compressor is running or pressurized. Stop the compressor and
WARNING relieve all internal pressure before doing so.

15.3
 BLOCK DIAGRAM OF LUBRICATION SYSTEM

Functions of various systems

15.4

LUBRICATING SYSTEM
Model : PG 350 - 200 \ PG 400 - 175
PG 600 -100 \ PG 380 - 200 \ PG 400 - 150 PG 400 - 175 AC
Functions of various systems

Cooling and Lubrication System

The cooling and lubrication system consists of the fan, shroud, oil cooler,
oil filter and thermal valve.

The pressure in the receiver/sump causes a fluid flow from the sump to
the airend through the oil cooler, thermal valve and oil filter.

The thermal valve is fully closed when the oil temperature is 155OF.
REFER TO THE PARTS LIST FOR THE TYPE OF THERMAL VALVE
USED ON A PARTICULAR MODEL.

As the discharge temperature rises above 155OF due to the heat of

compression, the oil temperature rises and the thermal valve begins to
close the oil line from the tank to the airend through the oil filter to
divert the oil through the oil cooler. Depending on the oil temperature,
the thermal valve opening position ensures that the temperature of the
oil at the inlet of the airend is maintained by

a) fully allowing the oil from the tank to the airend;

b) fully allowing oil from the cooler to the airend; and

c) mixing oil from the tank with oil the cooler before it goes to the airend.

When the machine is started the oil temperature and pressure are low.
The oil separated from the air–oil mixture in the receiver tank flows
through the return line (scavenge line) to the airend.

This continues till the required pressure is built up in the receiver tank.
As the compressor continues to operate, the temperature of the oil
also rises.

Once the intended pressure is built up in the receiver tank, oil starts to
flow to the main line by the pressure differential through the oil cooler,
main oil filter, bearing oil filter and oil stop valve to the airend in large
quantities, that is, from the high-pressure region in the receiver tank to
the low-pressure region in the airend. The return line is operated
throughout the whole process.

The oil cooler is so arranged that the lubricating and cooling oil flowing
internally through the core section is cooled by the air stream from the
cooling fan flowing past the core section. When dirt accumulates on
the external surface of the oil cooler, its efficiency is improved. It is
recommended that the oil cooler be cleaned every month by directing
compressed air through the core of the oil cooler.

15.5
Functions of various systems

COOLING SYSTEM

15.6
Functions of various systems

After being cooled the oil is filtered in preparation for injection into the
compression chamber and bearings of the compressor unit. The filter
has a replaceable element and a built-in bypass valve which allows
the oil to flow even when the filter element becomes clogged, requiring
a change of the filter element, or when the viscosity of the oil is too
high for an adequate flow.

After the oil is properly filtered, it flows through the oil stop valve to the
compressor unit, where it cools the seals and the compression chamber
and lubricates the bearings and gears.

The oil stop valve functions when the unit is shut down. It shuts off the
oil supply to the airend. The oil stop valve is held open by a pressure
signal from the airend when the compressor runs. When it shuts down,
the pressure signal is lost and the oil stop valve closes, isolating the
airend from the cooling system.

A portion of the oil flowing to the airend is routed to a bearing oil filter. All
the oil flowing to the gears, the shaft seal and the internal bearings of the
compressor unit flows through this extra-fine filter, ensuring that the
cleanest possible oil is supplied to these components. This filter also
has a built-in bypass valve and a replaceable element.

Lubricating System
Model : PG 450-150

15.7
Functions of various systems

Single - Stage Starting Mode

15.8
Functions of various systems

Starting Mode

Check the engine oil level, radiator water level and compressor oil level

Before starting the engine, set the engine RPM at high idle, and set
open the suction BFV fully

Close the service line ball valve

Switch ON the isolator

Switch on the Toggle switch : GREEN bulb (indicates ready to start) and
RED bulb (indicates the power supply to the panel) GLOW

Put the ignition key in the ignition override switch

Turn the Ignition switch (one turn)

Turn the ignition switch again (second turn) and hold

When engine builds up speed, release the ignition key as soon as the
engine fires

The pressure inside the sump develops and when it reaches

above 4 bar, the MPV opens and releases the air into service

Open the service line ball valve for use

15.9
Functions of various systems

Single - Stage Starting Mode

15.10
Functions of various systems

Capacity Control System for Single-Regulator System

The functional description of the capacity control system is described
below in three distinct phases of operation. This description applies to
the entire control system, with the exception of the pressure setting,
which depends on your pressure requirements and can be adjusted using
the pressure regulator.

Check the engine oil level, radiator water level, compressor oil level.

Before starting, set the engine RPM at 2100 (HIGH IDLE) and open the
suction BFV fully.

Close the service line ball valve fully.

Open the control line ball valve(red colour) fully (the handle should be
horizontal).

Switch on the isolator.

Switch on the toggle switch. The green bulb (indicates that the machine
is ready to start) and red bulb (indicates that there is a power supply to
the panel) glow.

Put the ignition key in the ignition override switch.

Turn the ignition switch (one turn).

Turn the ignition switch again (second turn) and hold it.

When the compressor is started, atmospheric air is drawn through the
butterfly valve, compressed and discharged to the air–oil receiver. The
pressure builds up in the receiver tank from 0 to4 kgf/cm2.

During this period the pressure regulator valve and the actuator are
inoperative. The actuator holds the butterfly valve fully open and the
compressor operates at the full rated capacity.

As the compressor operates at full capacity, the engine runs at the rated
speed.

The rising receiver tank pressure is not communicated to the service
line because of the minimum pressure valve, which is set at 4 kgf/cm2.

Hold the ignition switch key for 3 to 4 seconds

Now release the ignition override switch.

The pressure inside the sump builds up. When the pressure exceeds 4
bar, the MPV opens.

15.11
Functions of various systems
Single-stage Loading Mode
15.12
Functions of various systems

Loading Mode

Once the pressure inside the sump reaches the set pressure (working
pressure), the air from the MPV enters the pressure regulator

The NC (normally closed) pressure regulator, which is designed to

open at working pressure, will turn into open type (POSITIVE
REGULATOR) and sends the air pulse through the pulse lines hoses

There are two pulse line hoses. One of the pulse line hoses is connected
to butterfly valve actuator and the other pulse line hose is connected to
engine governor actuator

The pulse line which goes to the butterfly valve actuator moves and
opens the butterfly valve according to demand

The pulse line that goes to the engine governor actuator moves and
reduces or increases the speed of the engine according to demand

Close the service line ball valve

15.13
Functions of various systems

Single-stage Unloading Mode

15.14
Functions of various systems

Unloading Mode (Low idle RPM)

Pressure in the tank raises above working pressure

Pressure regulator gets more air than the set working pressure

The air, from the pressure regulator enter the pulse lines

One pulse lines gets connected to the butterfly valve actuator and
closes the suction completely

Other pulse line goes to the governor and reduces the speed of the
engine from full load speed to Low idle RPM

Based on service line demand, the butterfly valve suction will open and
close. The engine RPM will vary according to the demand

This cycle continues according to air demand

15.15
Functions of various systems

Modulation

When the amount of air being used is less than the rated capacity of the
compressor, the service line pressure rises above the operating pressure.
The pressure regulator valve opens gradually, applying pressure on the
actuator. This causes the actuator rod to partially close the inlet butterfly
valve and reduce the speed of the engine. As the pressure increases, the
actuator rod closes inlet of the butterfly valve further and continues to reduce
the engine speed until it reaches the loaded speed.

The actuator has an orifice in its cover, which vents a small amount of air to the
atmosphere when the pressure regulator valve is open. This allows the actuator
to vary the air intake to match the air demand. The orifice also bleeds any
accumulated moisture from the actuator. The compressor continues to run in
this manner until the demand for air increases. As the demand increases, the
receiver tank pressure falls to the operating pressure. The pressure regulator
valve closes, the air inlet valve opens fully and the engine runs once again at
the rated speed.

Shut Down
The blow down valve is held closed by a pressure signal from the compressor
unit. When the compressor is shut down the pressure signal is lost and the
blow down valve opens, venting the air in the receiver tank to the atmosphere.

15.16
 Functions of various systems

CONTROL SYSTEM DATA

SI MODE PG 400-175
PG 450-150 PG 350-200 & PG 600-100 PG 400-150 PG 380-200
No. DESCRIPTION
PG 400-175 AC

1. Working pressure 10.5 14.06 12.3 7 10.5 14.0

- (kg/cm2) (100 psig) (200 psig) (175 psig) (100 psig) (100 psig) (200 psig)

2. Start mode
0 - 4.0 0 - 4.0 0 - 4.0 0 - 4.5 0 - 4.5 0 - 4.5
- (kg/cm2)

3. Normal operating
10.5 14.06 12.3 7 10.5 14
mode - (kg/cm2)

4. Modulating mode
10.0 -10.5 13.5 -14.06 11.8 -12.3 6.5 - 7.0 10.0 - 10.5 13.5 -14.0
- (kg/cm2)

5. Shut down
4.0 - 0 4.0 - 0 4.0 - 0 4.5 - 0 4.5 - 0 4.5 - 0
- (kg/cm2)

15.17
Functions of various systems

Trolley system

15.18
Functions of various systems

Trolley System

The structure of the compressor is made of formed channels adequately

designed with cross-beams and dimensioned to withstand the basic weight,
forces acting during the running of the compressor and forces acting during
towing. The leaf springs, axles and wheels are designed and selected to
withstand static and dynamic loads. Refer to the figure given below to
understand the parts of the base system. Refer to the parts manual for the
part numbers.

15.19
Functions of various systems

Canopy system

15.20
Functions of various systems

Canopy System

The canopy assembly is made of multiple panels for ease of manufacturing

and assembly/disassembly. The canopy design ensures that there is an
adequate flow of air into it and hot air flows out without any restriction when
the compressor is run with all the doors closed. Refer to the figure given
below to understand the various parts of the canopy. Refer to the parts manual
for the part numbers.

15.21
Functions of various systems

Engine system

15.22
Functions of various systems

Engine System

The diesel-powered engine supplied is rated for continuous duty application

at full load. The engine, with all accessories, will run trouble-free provided
the periodic maintenance is done as per the recommendations given in the
engine manual. The diesel tanks mounted on the base frame are of adequate
capacity to run the compressor at full load for 8 hours.

15.23
Lubrication Oil

For regular maintenance and inspection of the engine, contact the nearest
Cummins dealer.

Oil performs a very critical function in an oil-flooded screw-type air compressor.

This takes away the major part of the heat of compression, seals all the areas
and lubricates the bearings and gears. The important criteria of a lubricant
for a screw compressor are its

viscosity

wear characteristics

demulsibility

heat resistance

thermal stability

Elgi Air Lube is blended using heavy-duty hydraulic-based oils with appropriate
amounts of additives to ensure satisfactory compressor performance.

The life of a synthetic oil is determined by the operating temperature. For every
10OC above 120OC, the life of the oil goes down by almost 30–40%. It is
recommended that the oil change frequency be varied in the summer months
and winter months to get the best out of the synthetic oil and the compressor.
A good record of the operating temperature of the compressor is essential to
do this. Continuous operation of the compressor at high temperatures beyond
120OC without changing the oil will lead to varnish formation and will affect
the life of the bearings and airend. If the compressor is kept idle for a long
period, the oil may deteriorate, depending on the storing conditions.
Please consult oil supplier for details..

The oil must be changed:

once in 500 hours if mineral oil is used

once every 2000 hours when a semi-synthetic oil is used

once in 4000 hours in the case of a synthetic oil

Use ISO VG 68 or an equivalent-grade oil for Elgi screw compressors.

15.24
Lubrication oil

RECOMMENDED ELGI OIL

Oil Change Elgi Contained

Elgi Oil Grade
Frequency Part number Volume

AIRLUBE 500 hours 000998043 210 Litres

00099805A 20 litres

AIRLUBE PLUS 1000 hours* 00099805B 50 litres

00099805C 210 litres

* For operating temperature above 90OC and dusty atmospheric conditions,

recommended oil change frequency is 800 hours.

• All the above figures are guide lines based on extensive trials in the field.
However our service engineers can help you to optimise the oil drain interval
for your application based on the operating temperature, pressure and the
environment condition.

The Discharge Temperature Switch is fitted on the air filter stand. It

shuts down the compressor if the discharge air-oil mixture temperature
reaches the preset value of 115OC . The probe is fitted on the airend
outlet cover or receiver tank.

15.25
Safety and Interlocking Devices

The Oil Level Indicator of the compressor is fitted at the compressor sump
(separator tank).This indicates the oil level in the sump before the unit is started.
When the machine is running, the oil level may not be readable.

The Line Pressure Gauge reading is taken from the dry air from the sump top
plate. This indicates the line pressure in all operation modes.

The Discharge Temperature Gauge reading is taken from the discharge line.
The maximum allowable temperature of the discharge air-oil mixture is 115°C in
the case of a mineral oil. This gauge indicates the overall system temperature.

The isolator is fitted on the panel for safety.

The Air Filter Indicator for the compressor and engine is fitted at the point of
entry of air to the filter assembly. This indicates the condition of the air filter.
When the air filter is choked the red-coloured stem moves forward and provides
an indication that cleaning is required. This also provides an idea of the restriction
level of the air filter element so that maintenance can be carried out accordingly
(either replacement or cleaning).

The Hour Meter measures the running hours of the engine.

The Manifold Pressure Gauge of the airend is fitted at the oil line manifold
(near the bearing oil filter line) to indicate the pressure of the oil going to the
bearings of both airends.

16.0
Safety and Interlocking Devices

Interlocking Devices

The following interlocking devices have been provided your compressor for
safe and reliable service.

The Minimum Pressure Valve is fitted at the outlet of the oil separator. It
maintains a minimum receiver tank pressure of about 4kgf/cm2 during all
conditions, which facilitates proper air-oil separation and circulation of oil to
the airend.

MINIMUM PRESSURE VALVE

16.1
Safety and Interlocking Devices

The Oil Stop Valve is located downstream of the bearing oil filter and upstream
of the airend. It cuts off the oil supply to the compressor unit when the unit is
shut down.

OIL STOP VALVE

The Pressure Regulator Valve can be adjusted depending upon your

pressure requirements. It is set to supply a pressurized air pulse to the single-
acting actuator, which in turn operates the butterfly valve to gradually open or
close the inlet port of the airend, in accordance with the outlet air pressure at
suction.

It also operates the engine governor lever to vary the speed between 1200 rpm
(idle) and 2200 rpm, or the rated speed, according to the air demand.

PRESSURE REGULATOR VALVE

16.2
Safety and Interlocking Devices

An actuator connected to the butterfly valve opens the butterfly valve or closes
it gradually in response to the pressure signal received from the pressure
regulator valve, thereby controlling the amount of intake air of the airend.

It also operates the engine governor lever to increase/decrease the engine

speed according to the demand.

ACTUATOR
The Blow Down Valve installed in the receiver tank serves two functions:

When the compressor starts up, the air pulse line from the outlet opens, which
in turn closes the blow down valve to permit the air-oil pressure to build up in
the air-oil receiver tank.

When the machine is shutting down, the air pulse line from the outlet closes,
which in turn opens the valve to bring the tank pressure down to atmospheric.

BLOW DOWN VALVE

16.3
Safety and Interlocking Devices

The Discharge Check Valve is used for automatically limiting the flow in a
piping system to a single direction. This (non-return) valve is installed between
the airend and the separator tank inlet point to allow the air-oil to flow in one
direction alone so that the air filter is protected from a sudden reverse flow of
the air-oil mixture from the receiver tank when the unit trips.

When the machine is running, the air-oil mixture moves from the airend outlet
to the air-oil receiver tank.

DISCHARGE CHECK VALVE

The Thermal Valve allows the oil to flow from the receiver tank to the oil filter
when the temperature is less than or equal to the "start to move temperature".
It also bypasses the oil to the oil cooler when the temperature is above the
"cracking temperature". This maintains the dew point temperature of the whole
cooling system.

THERMAL VALVE

16.4
 Electrical System and Control
Elements
INSTRUMENT PANEL

INSTRUMENTATION SYSTEM INSTRUMENTATION SYSTEM

( PG 350 - 200 \ PG 400 - 175 ( PG 450-150)
PG 600 -100 \ PG 380 - 200 \ PG 400 - 150
PG 400 - 175 AC )

17.0
Electrical System and Control
Elements
System Components and Description

The electrical system comprises not only the equipment necessary to operate
the compressor but also a system included to shut down the machine in the
event of a malfunction. The components of the electrical system are an engine
starter with an integral solenoid, batteries (one or two as the case may be)
and an alternator with a built-in voltage regulator.

The electrical control system consists of the following:

12 V battery (2 Nos)

Fuel level indicators

Alternator with built-in voltage regulator

Ignition/override switch

Discharge temperature switch

Engine starter with integral solenoid

Hour meter

Indicating lamps

Instrument Panel

The instrument panel consists of a line pressure gauge, discharge temperature

gauge, engine oil temperature gauge, engine water temperature gauge,
engine oil pressure gauge, ammeter, start button, override key, engine stop
knob, tach-hour meter and indicating lamp.

The functional locations of the following controls are as follows.

Charging failure : Glows when alternator is not charging.

Override Key : Turn key to check all electrical connection. Turn further
to override all switches.

17.1
Electrical System and Control
Elements

The line pressure gauge is connected to the dry side of the receiver
tank and continually monitors the service line air pressure.

The discharge temperature gauge monitors the temperature of the air

and oil leaving the airend.

The line pressure gauge is connected to the wet side of the receiver
tank and continually monitors the sump air-oil pressure.

The fuel level gauge is connected to the diesel tank and monitors the
level of fuel in the tank in trolley units.

All the engine parameters like RPM, run hours, engine oil pressure, engine
water temperature will be displayed in the digital cluster. All the engine side
safety will be take care by this cluster. i.e., Engine high water temperature,
engine low oil pressure over cracking protection.

17.4
For the wiring harness the following gadgets are used (wiring harness Part no: 038360154)

SI. No. Description Part No. Qty

1 Isolator 40A SP 008927070 1

2 Isolator 40A DP 008927071 1
3 Line Pressure Gauge B212104 1
4 Illumination on/off Switch 008940060 1
5 Discharge Temperature gauge B002000210005 1
6 Ignition key Switch Cummins Scope(504975) 1
7 Arya Cluster Cummins Scope(2868389) 1
8 Fuse 40 A 038400019 1
9 Fuse 15A 038400015 1
10 Fuel Level 031406020 1

Electrical SPL and model

TPL no
X0380041 :

PG 450-150 S03159

PG 400-175 S03186

PG 350-200 S03187

PG 600-100 S03190

PG 380-200 S03191

PG 400-150 S03192

PG 450-150 CE S03170

Dashboard 6BT Engine Compressors

17.5
Starting procedure - 6BTA Unit

Step-1 : Normal Condition Switch-on Condition

Close the outlet ball valve.

Switch ON the power supply to the compressor (Push the isolator switch upwards).

Step-2 :
Normal position Start position

Turn the over ride key clockwise to start position.

Step-3 : Over ride position

Further turn the over ride key to over ride position for 5 seconds (till the engine speed reaches
250 ) & release it. Then over ride key automatically comes to start position and compressor will
starts its operation and increase the machine working pressure.

17.6
Electrical System and Control
Elements
Purpose of Controls

NO. CONTROL OR PURPOSE

INDICATOR

01. Over ride switch Turn key to check all electrical connections. Turn
key further to override all switches. Release the key
once engine starts.

02. Discharge oil Monitors the temperature of the air-oil mixture leaving
temperature gauge the compressor unit.

03. Oil sight glass Monitors the oil level in the receiver tank. Check oil
temperature gauge level only when machine is shut down.

04. Oil stop valve Cuts off flow of oil to the compressor unit when the
machine is shut down and allows a flow of oil to the
unit when starting up.
05. Minimum pressure Maintains a minimum pressure of 3-4 kgf/cm2 in
valve the receiver tank. This valve restricts the air
discharge from the receiver tank to the service line
when the pressure falls below 3-4 kgf/cm2. However
the full flow is allowed at the normal operating
pressure.

06. Single-acting Regulates the amount of air entering the inlet

actuator valve.

This regulation is determined by the amount of air

being used at the service line.

07. Pressure regulator Opens a pressure line between the receiver tank and
valve actuator, allowing the actuator to regulate the air
delivery according to the air demand.

08. Pressure relief Opens when the pressure in the tank exceeds the
valve designed value.

17.7
Electrical System and Control
Elements
Cummins Instrument Cluster working principle

Features of the cluster.

The cluster has a full control on the engine running.

At a fault occurrence the cluster will trip the engine.

It facilitates in displaying parameters as Engine Water Temperature, Engine Oil
Pressure, RPM, Battery Voltage, and Running hours.

It avoids running of starter motor under engine running, when any accidental
start-key press is made.

Stops the cranking automatically after the engine cross 299RPM even if the
operator continues to press the start key.

It will not allow the Engine to start while the battery was in low voltage
i.e.19V DC

Warning alarm provided for temperature and low oil pressure which exceeds
100 degree low oil pressure when it drops beyond 1.1 bar

When temperature exceeds 102 degree it will trip the engine and also when the
pressure drops below 0.8 bar the unit will shutdown.

10 second delay for start the engine. In order to increase the lifecycle of starter
motor.

IP64 Ingress protection, Reverse Polarity, Voltage spike protection.

17.8
Electrical System and Control
Elements
Starting System
The cluster has a self timing system for starting purpose, it has an internal relay to
operate the pull coil. If we continuously hold the key switch in 3rd position it will
make the pull coil ‘on’ and the starter motor will crank the engine, if the engine can
start, the starter motor will be automatically put off after the engine RPM cross 299
RPM. If the engine is not able to start then the cluster will make the pull coil to be
‘On’ for 10secs and ‘Off’ for 10 secs and there will be three cycles like this after
that pull coil and hold coil* will be off.

Safety Operation
For this system the cluster will monitor the Engine Pressure and Temperature
sensor value If any thing Goes wrong with the pressure and temperature immediately
the Cluster will trip the engine. And also if the Compressor Temperature Exceeds
the limit automatically it will cut the hold coil supply and stop the engine.

LCD hour meter not working.

To run the LCD hour meter under ignition on position there must be at least any one
of the following parameter should be present

Pressure > 15 PSI

Alternator W point >24V or the wire is open

RPM signal greater than 500 rpm
So if any one is ok, LCD will start counting, if the engine crosses 500 rpm and goes
below and if other two parameter also not available the hour meter will not work(blink)
And the engine will trip after 5 secs and if any of the signal comes before 5 sec it
will not trip the engine.

Battery charge failure

This is only a failure indication to the engine operator and it will not trip the engine.

NOTE
Hold coil will get On when we switch on the ignition key.
After the pull coil pulls the plunger which will be holded by
the hold coil.

17.9
Maintenance

General

As you read this section, you will see that the maintenance programme of the
unit is quite minimal but important. The use of the service indicator provided
for the suction filter alerts you when service maintenance is required.

For the maintenance requirements of the engine, refer to the engine manual,
which provides detailed service instructions.

Daily Operation

Before starting the machine, it is necessary to check the oil level in the receiver
tank. Should the level be low, add the necessary amount. If the addition of oil
becomes too frequent, a problem has developed which is causing this
excessive loss. Refer to the troubleshooting section (excessive coolant
consumption) for a probable cause and remedy.

After a routine start has been made, observe the instrument gauges and be
sure they monitor the correct readings for that particular phase of operation.
It is recommended that after the machine has warmed up a general check on
the overall machine and instruments be made to ensure that the compressor
is running properly.

WARNING
Do not remove caps, plugs or other components when
the compressor is running or pressurized. Stop the
compressor and relieve all internal pressure before doing
so.

18.0
Maintenance

Maintenance Checklist: After 500 Hours of Running

Change the main oil filter element.

Change the compressor oil.

Check the tension of the fan belt.

Check the control system (regulator, actuator, hoses).

Clean the return line strainer.

Check the electrical system.

Check all the gauges function.

Check and clean the radiator and cooler externally.

18.1
Maintenance

Maintenance Checklist: After 1500 Hours of Running

Check and change the main oil filter element.

Change the compressor oil.

Check and change the separator element.

Check the tension of the fan belt.

Check the control system (regulator, actuator, hoses).

Clean the return line strainer.

Check the electrical systems.

Check all the gauges function.

Check and clean the radiator and cooler externally.

Maintenance Checklist: After 3000 Hours of Running

Check and change the main oil filter element.

Change the compressor oil.

Check and change the separator element.

Check the tension of the fan belt.

Check the control system (regulator, actuator, hoses).

Clean the return line strainer.

Check the electrical systems

Check all the gauges function.

Check and clean the radiator and cooler externally.

18.2
Maintenance

Check the condition of the airend bearing using an SPM meter.

Check and replace the tyre coupling element.

Check the shaft seal for any leakages and replace if required.

Clean the receiver tank thoroughly.

Maintenance Checklist: After 5000 Hours of Running

Check and change the main oil filter element.

Change the compressor oil.

Check and change the separator element.

Check the tension of the fan belt.

Check the control system (regulator, actuator, hoses).

Clean the return line strainer.

Check the electrical system.

Check all gauges function.

Check and clean the radiator and cooler externally.

Check the condition of the thermal valve.

Check the condition of the airend bearing using an SPM meter.

Check and replace the tyre coupling element.

Check the shaft seal for any leakages and replace if required.

Clean the receiver tank thoroughly.

Check the shaft seal for any leakages and replace if required.

NOTE
The change hours are given as guidelines for normal
operating conditions and may vary depending on the site
conditions.

18.3
Maintenance

OIL FILTER—Spin On Type

Oil Service Procedure

Drain the old oil from the sump/separator tank.

Drain the old oil from the oil cooler inlet/outlet points.

Remove the oil filter elements (main oil filter/bearing oil filter/return line
filter).

Rotate the coupling assembly by rotating the engine fan and remove the
oil completely from the separator tank.

Replace the main oil filter element.

Refit all the plug of the sump, oil cooler and oil filters.

Use 27 litres of a recommended oil.

Run the unit for a few minutes and stop the compressor after closing the
service ball valve.

18.4
Maintenance

Re-check the oil level in the sump. It should be at the half mark of the
glass after the fumes settle down. If necessary, add oil.

Change the air filter element after every 1000 hours of running.

Change the separator element after every 1500 hours of running.

Clean the radiator and oil cooler using an air jet with a pressure of 4 bar
only after every 1000 hours of running.

After 2000 hours of running, in addition to all the above, clean the receiver
tank thoroughly. Also check each of the accessories independently to see if it
functions and replace the components as necessary.

RECOMMENDATION FOR OIL FILTER-FITTED UNITS

Change the main oil filter element (1 nos.) after every 500 hours of running.

Change the air filter element after every 1000 hours of running.

Change the compressor oil after every 500 hours of running (mineral oil).

Change the separator element after every 1500 hours of running.

18.5
Maintenance
Maintenance

18.7
Maintenance

RECOMMENDATION FOR ENGINE CONSUMABLES

MAINTENANCE

Change the engine oil after every 250 hours of running.

Change the engine lubrication oil filter kit after every 250 hours of running.

Change the engine fuel filter after every 250 hours of running.

Change the engine air filter after every 1000 hours of running.

Change the corrosion-resistant filter of the engine after every 250 hours
of running.

Change the engine bypass filter after every 250 hours of running.

Separator Element
The separator element must be changed after every 1500 hours of running.
Order the separator element kit. Follow the procedure listed below for
separator replacement.

Relieve the oil pressure from the receiver tank and all fluid lines.

Disconnect all the piping connected to the receiver tank cover to isolate
the receiver tank from return lines, the service line, etc.

Loosen and remove the hex head bolt from the cover plate.

Lift the cover plate from the receiver tank.

Remove the separator element.

Inspect and clean the receiver tank for rust, dirt, etc.

Place the new separator element in the receiver tank, taking care not to
dent it against the tank opening.

Clean the bottom of the receiver tank and remove any rust.

Replace the cover plate and fasten the cover on the receiver tank.

Reconnect all piping. While doing so, make sure that the return line tubes
have a dimensional clearance of ¼” above the bottom of the separator
element. This will ensure that there is a proper oil return flow to the
compressor.

Clean the return oil strainer before restarting the machine.

18.8
Maintenance

AIR FILTER

18.9
Maintenance

Air Inlet Filter Cleaning Procedure

When the air filter clog indicator indicates a blocked condition, remove the air
filter and replace it with a new air filter.

Never clean the air filter with compressed air.

Place a bright light inside the element to inspect it for damage or leak
holes. Light rays will pass through the element where holes are present
and destroy the same.

Inspect all gaskets and gasket contact surfaces of the housing. Should
faulty gaskets be evident, correct the condition immediately.

If the clean element is to be stored for later use, it must be stored in a

clean container.

After the element has been installed, inspect and tighten if necessary all
air inlet connections prior to resuming operation.

18.10
Maintenance

Casing

Hex. Bolt

Spring washer

Element

Hub

DRIVE COUPLING

18.11
Maintenance

Drive Coupling
Dismantling

Whenever major repair/overhauling is carried out on the unit, the airend should
be removed. The following dismantling and assembling procedure is to be
followed.

Unscrew the bolts on the engine flywheel.

Unscrew the bolts on the adaptor ring.

Remove the airend bottom support screws.

Lift the airend along with the drive coupling and place it on the work
table.

Unscrew the bolt connecting the rubber element to the hub.

Using a puller remove the hub from the airend shaft.

Clean all the components thoroughly. If any component is found damaged,

replace it with a new one.

Use the following torque values for tightening the screws.

No. Aluminium casting to fly wheel Coupling element locking bolts to hub
Grade 8.8 Torque (Nm) Grade 8.8 Torque (Nm)
01 3/8" 34 M16 175

18.12
Maintenance

Assembling

Check the engine crankshaft end play using a dial gauge in the following
manner. Remove the engine inspection door. Position the crankshaft
at any end using any lever and measure the run-out of the crankshaft
at the fan side using a dial gauge. Then move the crankshaft to the
other end using the lever and measure the end play as well as the run-
out.

Measure the depth of the mating face of the engine housing and engine
flywheel.

Assemble the aluminium drive disc on the flywheel.

Assemble the adapter ring on the airend mounting face.

Clean the hub bore and insert it on the compressor shaft using a pusher.

Assemble the rubber element with the hub.

Now take the airend to the engine and couple them by clamping the
adaptor ring with the engine flywheel.

Assemble all the components of the drive coupling with the required
torque.

NOTE
A drive coupling operating in a correctly assessed system
requires no maintenance. It is recommended that the
rubber blocks/rubber diaphragm be inspected every 2500
hours.

NOTE
A small amount of rubber dust is normal. Large quantities
of dust during initial running require inspection. During
assembly assemble all components of the drive coupling
with the proper torque values.

18.13
Maintenance
Control System Adjustment

The first step in adjustment of the control system is adjusting the control linkage
between the engine governor and actuator. Adjust the slider in such a way that
engine reaches its full rated speed when the engine is started. At the full rated
speed of the engine the butterfly valve should be fully open or approximately
15–20° off the vertical.

NOTE
The value of 15–20°does not apply to the inlet valve lever.
The above adjustments have to be made prior to the final
adjustments.

Operating Adjustment

Start the compressor. Allow the unit to operate until the normal operating
temperatures are attained. Ensure that the service valve is fully open during
this time. Adjust the engine to operate at its full rated speed as per the
specification sheet.

Butterfly Valve Adjustment

The butterfly valve opens and closes with respect to the condition of the service
valve. The pressure regulator valve actuates the actuators of both the butterfly
valve and the engine governor according to the service pressure requirement.

Clean the butterfly valve after every 1500 hours of running. Remove and clean
the centre flap mating surface area.

BUTTERFLY VALVE
18.14
Maintenance

Pressure Regulator Valve Adjustment

Turn the pressure regulator valve screw clockwise to ensure that it is out of
adjustment. Start closing the service valve slowly till the rated pressure is
reached. The engine should operate at the rated speed with the compressor
so that a condition is obtained where the engine operates at the rated speed
to the rated pressure of the compressor.Turn the pressure regulator valve
screw counter-clockwise till the actuator begins to operate. Lock the adjusting
screw with a lock nut.

Continue closing the service valve slowly. The speed of the engine reduces
while the butterfly valve closes to match the output. At this time the pressure
regulator valve adjustment is complete.

PRESSURE REGULATOR VALVE

18.15
Maintenance

Idle Speed Adjustment

The last step in capacity control adjustment is adjustment of the engine idle
speed and compressor butterfly valve.

Continue closing the service valve. The speed of the engine will drop with a
constant working pressure and closing of the butterfly valve to match the
output of air. When the engine reaches 1250 rpm, adjust the stop screw at the
engine governor, thus preventing a further drop in the speed of the engine. Now
close the service valve fully. Once the engine is idling at the specified speed,
the inlet valve should be closed. Then the air pressure will stabilize at 1 kgf/cm2
more than the set working pressure.

By changing the hole position in the governor lever, you can set the idling
speed suitably.

18.16
Maintenance

MINIMUM PRESSURE VALVE

18.17
Maintenance

Minimum Pressure Valve

The details of the inner elements of the minimum pressure valve are shown
in the accompanying figure.

Minimum pressure valve maintenance is quite minimal. The only part which
normally requires replacement is the ‘O’ ring on the piston.

The minimum pressure valve cover is under heavy spring tension. Loosen the
cover bolts alternatively by one turn each to relieve the spring tension.

Before performing maintenance on the valve, be sure that the pressure has
been fully relieved in the machine receiver tank and that the downstream
pressure has been vented to the atmosphere.

Extreme caution should be exercised when removing the cap

! or cover from the body because of the spring tension.
WARNING

To replace the ‘O’ ring, follow the procedure explained below.

Evenly remove the cap to relieve the spring tension.

Remove the spring.

Remove the piston.

Remove the ‘O’ ring and discard it.

Clean the piston.

Replace the ‘O’ ring.

Coat the piston and ‘O’ ring with grease.

Replace the piston.

Replace the spring and cap.

18.18
Maintenance

OIL STOP VALVE

18.19
Maintenance

Oil Stop Valve

To use the repair kit, follow the instructions given below for proper installation.

Remove the cap screw securing the cylinder to the valve body and remove
the cylinder. Inspect for scratches, scoring, etc.

Disassemble the ‘O’ ring from the stem by removing the nylock nut at
the end of the stem.

Discard the ‘O’ ring and nylock nut. Replace these with the new ones
provided in the kit. When reassembling, replace the ¼" nylock nut also.

Remove and replace the valve body ‘O’ ring. Reassemble the cylinder nd
the valve body.

Remove the valve body, cap and spring.

Remove the valve seat from the stem by unscrewing it. Replace it with a
new one.

Remove and replace the gasket between the valve body cap and the
valve body. Use a new spring.

Reassemble the spring and cap.

18.20
Maintenance

Cap

Retainer

T-ring

Retainer

Piston

Stem

Disc

Seal washer

Body

Poppet

Spring

Gasket

Top cover

Washer
Hex screw

BLOW DOWN VALVE

18.21
Maintenance

Blow Down Valve

Blow down valve maintenance is limited to replacement of the cover gasket
and internal ring and seat.
Using the repair kit, follow the instructions given below for proper installation.

Remove the four screws on the top cover which hold the assembly
together.

Pull the top cover away from the body.

Remove the old gasket and replace it with the new one.

Align the top cover with the body, replace the four screws and tighten.

To replace the valve seat, loosen and remove the two socket head screws
in the bottom cover.

Pull the bottom cover from the main body.

Remove the cover ring, spring, seat cup and seat. Discard the seat and
ring, and replace them with the new ones in the kit.

Reassemble the bottom cover.

18.22
Maintenance

Valve seat

Plunger

Spring

Body

DISCHARGE CHECK VALVE

18.23
Maintenance

Discharge Check Valve

To dismantle the discharge check valve, follow the instructions given below.

Dismantle the flexible hose on the discharge piping between the airend
and the receiver tank.

Dismantle the hose adapter and the reducing bush fitted on the valve
outlet port.

Unscrew the valve housing from the compressor unit.

The assembly should now fall away from the compressor unit.

Remove the three Allen screws on the housing.

Remove the plug on the housing and loosen the fourth smaller Allen
screw.

The adapter can be separated from the housing.

Check the spring and plunger for polishing or wear.

Place the spring and plunger in position on the housing as they were
prior to disassembly.

Replace the plug screws to secure the cover to the housing and reconnect
all the disconnected piping.

Replace the flexible hose and start the machine to check for leaks.

18.24
Maintenance

PRESSURE REGULATOR VALVE

18.25
Maintenance

Pressure Regulator Valve

Pressure regulator valve maintenance requires replacement of the diaphragm.

Use only the repair kit. Follow the procedure given below for proper installation.

Loosen the lock nut and turn the adjusting bolt counter-clockwise until
the inner spring tension is relieved. The adjusting screw should turn
freely when the spring tension is relieved.

Remove the top housing from the bottom housing to allow access to the
internal parts.

Next remove the spring button and the spring. Loosen the pressure plate
nut on the top seat to replace the diaphragm. The replacement is available
in the repair kit.

18.26
Maintenance

SINGLE ACTING ACTUATOR

18.27
Maintenance

Single-Acting Actuator

The single-acting actuator requires a maintenance check every 6 months or

1500 hours of operation, whichever is earlier.

During this check, replacement of components is not necessary if they are in a

good condition. Thorough cleaning and lubricating of the moving components
should be sufficient. But once in a year all the sealing components and the
spring have to be replaced.

The procedure is given below.

Unscrew the bolts and nuts and then remove the end cover and ‘O’ ring.

Remove the plunger along with the plunger rod.

Check the cup seal. Change it if it is found damaged.

Remove the spring and check the stiffness.

Replace worn out/damaged components before assembling.

18.28
Maintenance

Airend Maintenance

This needs special tools, jigs and fixtures for repair work. Please contact the
Elgi dealer for any assistance with airend maintenance.

Oil Cooler and Radiator Maintenance

The compressor unit needs to be shut down before any maintenance work is
done on the oil cooler and radiator.

Oil cooler : Remove the ROC canopy cover and clean it using an air jet with a
pressure of 3 bar.

Radiator : Remove the fan guard and clean it.

Battery Maintenance

Clean the battery and surrounding area with a wet cloth dipped in a diluted
washing soda solution to remove the acid on the top. While doing so
ensure that the vent plugs are screwed on tight.

Clean the battery terminals in case they are corroded.

Apply petroleum jelly or Vaseline on the battery terminals and fixing
clamps.

If the level is low, top up with distilled water/DM water only (up to the
maximum level).

Check specific gravity of each cell at least once every 30 days in a
vehicle, and if the gravity is less than 1.19, put the battery on bench
charge after topping up to the maximum level.

When installing batteries in series (two-battery systems-12V), ensure
that both the batteries have the same specific gravity.

The electrolyte in the battery should be maintained up to the upper level
only.

Always keep the battery surface dry and dust-free.

18.29
Maintenance

Check for the following voltage setting:

Open circuit voltage: 12.5 V per 12 V battery
On top of charge voltage: 15.9 to 16.5 V per 12 V battery
On H.R.D. for 15 seconds: 10.5 V per 12 V battery
Vehicle charging voltage: 13.5 to 14.2 V per 12 V battery.

Ensure that the batteries are checked every month as per the checklist.

Ensure that charger/charging clips/other tools are clean and in order/
charging clips tight & free from corrosion.

Ensure that batteries are removed and kept away from welding area in
case of vehicle Maintenance.

NOTE
During replacement, compulsorily all the components
should be thoroughly cleaned and lubricated.

18.30
Maintenance

Flushing the Compressor

A. For new compressors

Drain the previous fluid from the sump, piping, filters and fluid cooler,
preferably while the fluid is hot.

Drain the fluid filter elements.

Drain thoroughly.

B. For dirty or varnished compressors.

Drain the previous fluid from the compressor while the fluid is still hot
and change the fluid filter(s).

Drain the dirty/solidified oil and fill the tank with Cabol 68 (supplied by
BPCL) cleaning fluid. Run the unit for 24 hours with this oil and drain
completely while it is hot.

After draining the cleaning fluid, fill with fresh oil. Check the condition of
the oil filter and separator every 250 hours.

After 2 hours drain the cleaner completely and change filter(s) if necessary.

Fill the compressor with compressor cleaner and allow it to run for 48 to
72 hours. Monitor the filter(s) and change if necessary.

Run the compressor for 1 hour, drain completely and change filter(s) if
necessary.

Drain thoroughly.

Submit a fluid sample for analysis after 200 hours run time.

NOTE
During clean-up, watch for differential pressure in the
separator. When the sump pressure becomes 10 lb
greater than the line pressure, change the separator.

NOTE
The above procedure is for a machine that is not too
badly varnished.

18.31
Trouble shooting

Engine not No fuel. Check fuel level and add fuel if necessary.
starting Clogged fuel filter. Replace the element.

Low battery voltage. Check electrolyte level and add water and recharge if
necessary.
The electrical connections for In any one of the switch the electrical connections (power
the following are to be checked supply to be checked) and if the power is not coming to the
switch please rectify / replace it and ensure that the green
1. Check Engine water temp light in the control panel is ON at the time of starting.
switch
2. Check Engine oil temp
switch
3. Check Engine oil pressure
switch
4. Check Compressor low
pressure switch
5. Check compressor high
pressure switch
6. Check compressor high
Temperature switch
7. Check engine solenoid
switch
8. Check loose connection in
control panel wires.
Loose battery cables. Tighten cables.

Dirty battery cables. Clean thoroughly.

Clogged air filter. Clean or replace the element.

Engine problems may have Refer to your Engine Manufacturer

developed.

Fuel not reaching the pump. 1. Checks the NRV fitted before the moisture filter and if
necessary replace it.
2. Airlock in diesel hose line to be removed
3. Air Lock in fuel filter
4. O ring not seated properly in fuel filter
5. No fuel in the fuel filter
Diesel tank id fitted very below the engine.
Engine starts and Blown fuse. Check electrical continuity and replace if necessary.
stops immediately

Engine oil
temperature and Clean cooler and check for proper ventilation.
water temperature
is high

19.0
Trouble shooting

Machine shuts No fuel. Check fuel level and add fuel if necessary.
down with air
demand present Compressor
discharge
temperature switch
is open.

a) Cooling airflow is Clean cooler and check for proper ventilation.

insufficient.

b) Low oil level in Add oil.

receiver tank.
c) Dirty oil Check the colour of oil (minerals in case) and it should be yellowish
only. If the colour changed please change oil with filters.

d) Clogged oil filter Change oil filter elements.

Defective discharge Check for a short or open circuit to the fuel solenoid should this check
temperature switch out normal, it would be possible that the temperature switch itself is
defective.
Engine water
temperature switch
is open.
a) Cooling air flow Clean the radiator core.
restricted.
b) Low water level. Fill the radiator with adequate water.

c) Defective switch. Replace.

d) Blow fuse in Check continuity and replace if necessary
wiring harness.

19.1
Trouble shooting

No building of Air demand too great. Check service lines for leaks or open valves.
Line pressure Dirty air filter. Check the filter indicator and change or clean element if
required.

Pressure regulator valve out Adjust pressure regulator valve according to control
of adjustment. adjustment instruction in the maintenance section.

Defective pressure regulator. Check diaphragms and replace if necessary.

Defective minimum pressure Check and ensure piston is moving freely.

valve.

Improper unloading Pressure regulating valve is Re-adjust.

with an excessive set too high.
pressure builds up Leak in the control system Check control lines.
causing pressure causing loss of pressure signal.
relief valve to open.
Defective diaphragm in the Replace diaphragms.
actuator. (kit available)

Defective pressure regulator Repair the valve.

valve. (kit available)

Inlet valve jammed. Repair / replace the valve.

Restriction in the control Check all control lines and components and remove the
systems foreign particles clogging the system.

Jammed control linkage. Free the jammed portion of the linkage and adjust if
Clogged air/oil seperator necessary. Replace seperator element.
element.
Clogged air filter. Clean or replace the element.
Insufficient air
delivery Clogged air / oil seperator. Replace seperator element and also change the
compressor oil and oil filter at this time.

Faulty pressure regulator. Adjust or repair.

Engine speed too low. Re-adjust engine speed.

19.2
Trouble shooting

Excessive Clogged return line. Clean oil return strainer and orifice.
compressor oil Check DOT of the unit. It should be more than dew point temperature. Please refer
consumption the chart enclosed in last page of the manual.
(Oil carry over
Defective blow down valve. Replace kit.
through service
line) Check moisture level in the It should be 1/2 litre. If it is more than half litre rain of water
sump after shut down the from sump. Then replace the higher rated thermal valve.
unit
Leak in the lubrication Check all pipe connections and components.
system
Return line orifice chocked. Return line orifice may be chocked and needs to be cleaned.
Seperator element damaged Change seperator element.
or not functioning properly.
Orifice fitted in wrong Check the orifice and it should be fitted at outlet of return line
position. sight glass.
Excessive oil in the receiver Drain to correct level.
tank.
Vertical shell bottom welding Check welding condition.
condition.

Compressor Loose or broken fan belt. Tighten or change belt.

over heating
Dirty oil cooler core. Clean core thoroughly.
Clogged oil cooler tubes Clean tubes thoroughly.
(Internally & externally)
Low receiver tank oil level. Fill up to max. level.
Clog oil filter. Clean or change the mainoil filter and bearing oil filter.
Inter stage Pressure (first Check the pressure with a guage (provision is given for gauge
stage outlet) is high. fitment in first stage outlet cover) and it should be 3.5 bar max.
If the pressure is more please contact ELGI for rectification.
Clogged oil return line. Clean oil return strainer and orifice.
Wrong grade of oil. Drain and flush the system thoroughly. Use recommended
grade of oil.

Engine Loose or broken fan belt. Tighten or change belt.

over heating and Dirty radiator core. clean core thoroughly.
tripping
Faulty engine thermostats. Replace thermostats.
Clogged radiator. clean thoroughly.
Low oil level. Refill.
Other engine problems. Refer to engine manual.

Back flow of oil Check oil stop valve, service if necessary.

through suction Faulty oil stop
valve / DCV Check discharge check valve
when unit is
stopped

Oil throw through

BDV during shut
down
Faulty Blow Down Valve
Moisture Inspect, rectify or replace the kit.
condensation in
Receiver Tank (Air
Oil seperator
sump

19.3
Conversion Tables

Length (l)

From To Multiply by
Inches Millimetres 25.4
Metres Inches 39.37
Feet Millimetres 304.8
Metres Feet 3.281
Inches Thou 1000
Millimetres Micrometres 1000
Area (A)
From To Multiply by

Square metres Square feet 10.765

Square feet Square inches 144
Square inches Square Millimetres 645.16
Volume (V)
From To Multiply by
Cubic metres Cubic feet 35.315
Cubic feet Cubic inches 1728
Cubic metres Litres 1000
Cubic feet Litres 28.32
US gallons (liq) Litres 3.785
Imperial gallons (liq) Litres 4.546
Volumetric flow (Q)
From To Multiply by
Cubic feet per minute (cfm) Cubic metres per hour (m3/h) 1.6988
Cubic feet per minute (cfm) lpm 28.32
Cubic metres per hour (m3/h) lpm 16.667
Cubic metres per minute (m3/min) cfm 35.315

20.0
Conversion Tables

Mass (M)

From To Multiply by
Kilograms Pounds 2.205
Kilograms Grams 1000
Kilograms Ounces 35.27
Pressure (P)
From To Multiply by
Kgf/cm2 g Pounds/sq.inch(PSIg) 14.223
PSIg Pascals (Pa) 6895
Bar g kgf/cm2g 1.0197
Bar g PSIg 14.503
PSIg kgf/cm2g 0.0703
Temperature (T)
From To Conversion
Degrees Celsius (C) Degrees Fahrenheit (F) F= 9C/5 + 32
Degrees Celsius (C) Degrees Kelvin (K) F= C+273.15
Degrees Fahrenheit (F) Degrees Rankine (R) R= F + 460
Heat (Q), Work (W), Energy (E)
From To Multiply by
Ft-lbf Joules 1.35582
Ft-lbf Btu 0.001285
Keal kgf m 426.9
Joules Calories 0.2388
Btu/h Calories/h 252
Kilowatts Btu/h 3411

Power (P)
From To Conversion
Metric horsepower Kilowatts 0.7355
Imperial horsepower Kilowatts 0.7457

20.1
Torque values

The tightening torque values for bolts and screws used in Elgi
compressors are provided in this section for reference.

For Metric hex. head bolts and Screws Property Class 8.8

Thread size Tightening torque (N m)

M4 3
M5 6
M6 10
M8 25
M10 50
M12 87
M14 139
M16 214
M18 304
M20 431
M22 586
M24 745
M27 1090
M30 1480
M33 2013
M36 2586
M39 3346
M42 4135

21.0
Torque values

UNC hexagonal head bolts and screws — Grade 5

Thread size (inches) Tightening torque (N m)
¼ 12
5/16 23
3/8 41
7/16 65
½ 99
5/8 193
¾ 341
7/8 550
1 824

For NPT Fittings (Steel)

Thread size (inches) Tightening torque (N m)

1/8" 12
¼" 18
3/8" 22
½" 45
¾" 58
1" 79
1 ¼" 149
1½" 285
2" 420

For UNF Hex. Head Bolts and Screws—Grade 5

Thread size (inches) Tightening torque (N m)

1/4" 13
5/16" 25
3/8" 46
7/16" 73
1/2" 111
5/8" 217
3/4" 379
7/8" 602
1" 898

21.1
Disclaimers
Please read this document and the warranty terms accompanying the product carefully before using our
product. By purchasing our product, you agree that you will assume total responsibility and risk for your
use of the product. The warranty terms of the product have been provided separately.
1. ELGi is not liable for failure of the compressor ( hereinafter “compressor” or “product”) to perform its obligations
if such failure is as a result of Acts of God (including but not limited to fire, flood, earthquake, storm, hurricane
or other natural disaster), war, invasion, act of foreign enemies, hostilities (regardless of whether war is
declared), civil war, rebellion, revolution, insurrection, military or usurped power or confiscation, terrorist
activities, nationalization, government sanction, blockage, embargo, labor dispute, strike, lockout or interruption
or failure of electricity or telephone service and any other reasons beyond ELGI’s control.
2. ELGi does not take responsibility for any damage or injury resulting from neglecting the safety instructions,
warnings, cautions, precautions, or non-observance of the normal caution and care required for installation,
operation, maintenance and repair of the product, even if not expressly stated, and such instances are
specifically disclaimed by ELGi.
3. The entire literature including product description or any other information in this manual exclusively belongs
to ELGi and is subject to copyright. No person has any right to copy, modify, distribute, transmit, display,
perform, reproduce, publish, license, create derivative works, transfer or sell any information, or deal with the
same in any other manner, without the knowledge and written concurrence of ELGi, violation of which would
amount to infringement of rights of ELGi and would necessitate legal action.
4. The information published in this manual may include inaccuracies, or typographical errors. Changes may be
periodically added to the information herein. Any changes/improvements may also be made to the products
stated in this manual and ELGi is not liable if the readers are not updated with information.
5. Likewise ELGi is responsible only till the point of first sale to the ultimate customer and not thereafter and
only if the product is purchased from authorized dealers of ELGi. ELGi disowns liability on account of purchase
of any second hand product or purchase otherwise from unauthorized dealers. ELGi shall not be liable for any
indirect, incidental, punitive, special or consequential losses or damages including any loss of profit, loss of
production, loss of income or contract, loss of goodwill, expected savings or business relationships, arising
out of or in any way connected with the usage of the product or information in this manual.
6. In no event ELGi shall be liable for any claims or loss having a value higher than the original purchase price
of the product sold by ELGi or its network of authorised dealers.
7. These Disclaimers and the contents of this manual shall be subject to the laws of India and any disputes
pertaining to this manual or anything stated therein or any product stated therein is subject to the exclusive
jurisdiction of the courts in Coimbatore, Tamilnadu, India.
8. No liability in connection with the product will accrue to ELGi, If any welding or related operation involving heat
is carried out in the compressor. Never weld or modify any parts including pressure vessels.
k If any welding or related operation involving heat is carried out in the compressor. Never weld or modify
any parts including pressure vessels.
k If any damages to the product directly or indirectly arise due to long storage (6 months) of product and
subsequent corrosion of internal parts and which leads to fire or malfunctioning of the product.
k If the compressor package and its accessories are installed in such a way to allow moisture, rain, freezing
temperature or sun damage to affect the safe operation of the unit.
k If the person who operates / maintains the compressor does not adhere to all work related safety practices
and regulatory requirements.
k If unauthorized personnel other than ELGi authorized or trained personnel carries out commissioning,
installation, operation, maintenance and any repair work on the compressor.
k If the compressor and the compressed air are used for unintended use or are misused.
k If the compressor is operated below or in excess of its pressure and temperature limits.
k If the compressor “ON/ OFF” switch is operated through remote control situated away from the compressor
location without giving any adequate notice / alarm before starting the product .
(C) Copyright ELGi Equipments Limited, India 2014. All Rights Reserved.

22.0
Business Reply Card

To

The Marketing Department,

Elgi Equipments Limited,
Singanallur,
Coimbatore

From
Name:
Position:
Name of organisation:
Address:
Telephone number:
Email address:
Date:

I would like to have more information on the following the Elgi products and
services :

Electric driven rotary screw compressors

Diesel powered rotary screw compressors

Oil-free rotary screw compressors

Driers

Filters

Reciprocating compressors

Vayu compressors

Dr. Vayu compressors for dental applications

Air Lube oil and other coolants

Maintenance services

Please send me your literature

Ask your Sales Engineer to call on me

23.0
Feedback Form

We at Elgi would like to serve you better. Please help us to know how we could
do this. Fill in the answers to the following questions and send this form to the
Marketing Department, Elgi Equipments Limited, Singanallur, Coimbatore.
1. How did you come know about the Horizon compressors?
Advertisement
Internet
Elgi Sales Engineer
Other user
Trade fair
Other (specify please)…………..
2. How do you rate the response of the Sales Engineer who called on
you?
1 2 3 4 5
Very poor Very good
3. How do you rate the technical capability of the Sales Engineer who called
on you?
1 2 3 4 5
Very poor Very good
4. How do you rate the technical details provided for the products?
1 2 3 4 5
Very poor Very good
5. What is your rating of the timeliness of the delivery of the machine?
1 2 3 4 5
Very poor Very prompt
6. What is your rating of the commissioning service?
1 2 3 4 5
Unsatisfactory Excellent
7. Please give your suggestions:
Name:
Position:
Name of organisation:
Address:
Telephone number:
Email address:
Date:
Thank you for extending your help and giving your time.

24.0