ELGI EQUIPMENTS LIMITED

DESIEL POWERED SCREW AIR COMPRESSOR

DL04012 WITH 4BT (24 V SYSTEM)

SPARE PARTS MANUAL

Fab. No ....................

Elgi Industrial Complex, Trichy Road

Singanallur, Coimbatore - 641 005. INDIA.
ELGI EQUIPMENTS LIMITED
Coimbatore – 641 005, INDIA

Document Ref. No. : 03 91 150 30

Revision Status: R01

First print:
Second Print : 10/08/07

Printed in India

Price: INR

Compiled by

Rotary Compressor Division

 SCREW AIR COMPRESSOR

Table of Contents

Section 1 PART LIST OF VARIOUS SYSTEMS Page

No.

1.1 Air Inlet System 4

1.2 Discharge System 7

1.3 Cooling System 10

1.4 Lubrication System 13

1.5 Trolley System 15

1.6 Canopy system 16

1.7 Engine System 18

1.8 Control System 22

1.9 Electrical Circuit 26

1.10 Instrumentation system 28

Section 2 RECOMMENDED SPARES 29

2
 SCREW AIR COMPRESSOR

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 are
known for their reliability, maintenance, friendliness and safety. Every
Screw Type Air Compressor is designed keeping in mind three key quality
consideration viz.,

1. Energy Efficiency
2. Air Quality
3. 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.

This Parts Manual has been specially designed keeping you in mind, so that
you can get the most out of ELGI Compressor. This Manual contains
schematic views and parts lists for various sub-assemblies of the
compressor.

All information and illustrations 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 must be made available to the maintenance personnel at all

times.

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

Contact ELGI dealer / representative for any assistance. Always indicate

the Model and Fabrication number in your communication.

3
 SCREW AIR COMPRESSOR

1.0 Functions Of Various Systems

1.1 AIR INLET SYSTEM

• The air inlet system as shown below comprises of a dry type filter,
which filters the inlet air and prevents foreign particles from entering
the air end. Further, it has an indicator for air filter maintenance.

• The indicator located on the air filter exhibits red when the filter
maintenance is required.

• The air inlet valve directly controls the amount of air into the air end.
The opening or closing of the valve disc controls the port area in
response to the function of the capacity control system.

4
 SCREW AIR COMPRESSOR

15

14

13

19

14

17
18 11
16 2

12

10

20

10
21
6

5
6
21 21
6
4
7
2
3

AIR INLET SYSTEM

5
 SCREW AIR COMPRESSOR

1.1.1 Air Inlet System

SL.NO DESCRIPTION PART CODE QTY
1 AVM PC140A TYPE1 B141423 1
2 WASHER SPRING REC SEC M12 000996112 6
3 WASHER PLAIN M12 000996012 2
4 BOLT HEX M12X25 8.8 ZYP 5-8M 000906182 2
5 BRACKET,AIREND SUPPORT 030486300 1
6 WASHER SPRING REC SEC M16 000996116 7
7 WASHER PLAIN M16 000996016 1
8 GASKET A/E CU159 INTAKE 010431170 1
9 SPACER RING 035300059 1
10 GASKET, BFV, 4",RELEASE" 220412000 2
11 BOLT HEX M12X60 8.8 ZYP 5-8M 000906189 4
12 DUCT A/E TO AIR FILTER 030346270 1
13 ELBOW; RUBBER; 4NB" 220375400 1
14 CLAMP;T BOLT 4 ½” B50XX02 2
15 AIR FILTER ASSY-300 CFM B47XX07 1
16 BOLT HEX M8X20 8.8 ZYP 5-8M 000906115 2
17 WASHER PLAIN M8 ZYP 000996008 2
18 WASHER SPRING REC SEC M8 000996108 2
19 NUT HEX M8 8 ZYP 000948008 2
20 VALVE ASSY, BUTTERFLY, 4" 220210470 1
21 BOLT HEX M16X30 8.8 ZYP 5-8M 000906212 7

6
 SCREW AIR COMPRESSOR

1.2 DISCHARGE SYSTEM

• The Screw Air Compressor discharges compressed air/oil mixture into the
receiver tank.

• The compressed air/oil mixture enters the receiver tank tangentially wherein
heavier particles are separated and falls to the bottom of the receiver tank.
The separator element at final stage of air oil separation is the vital element
for getting clean air outlet. The separated oil collects in 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 ensures separated oil is
returned to the compressor by the pressure differential between the area
surrounding the separator element and the compressor inlet.

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

• A pressure relief valve (located on the wet side of the separator) is set to
open if the receiver tank pressure exceeds 40% more than working pressure.

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

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

7
 SCREW AIR COMPRESSOR

REV – 01 DISCHARGE SYSTEM

*ITEM NO – 47 – FOR FIELD REPLACEMENT OF OLD SYSTEM ONLY

37 39
35

34
15
24
22
18 23
20
3 13 19
36
31
17
21

16
30

29

47*
46
38

4 11 25
3

28 26
8
32 43
27
10 22
14 23
9
41
3 42
44
45

5
1

6 MODIFIED DISCHARGE SYSTEM

*RUBBER HOSE CHANGED IN FOR
METALLIC HOSE

8
 SCREW AIR COMPRESSOR
DISCHARGE SYSTEM
Sl.NODESCRIPTION PART CODE QTY
1 O RING DIA 69.44 X DIA 3.53 010453920 1
2 ADAPTER AIREND OUTLET 035300699 1
3 WASHER SPRING REC SEC M12 000996162 30
4 BOLT HEX M12X35 8.8 ZYP 5-8M 000906184 4
5 DISCHARGE CHECK VALVE - 60A B009801070002 1
6 GASKET, FLEX HOSE, 1 1/2 22047539A 1
7 GASKET DCV 60 A 035400013 1
8 DISCHARGE HOSE 035300702 1
9 BOLT HEX M12X90 8.8 ZYP 5-8M 000906195 4
10 PLUG; HEX; 1/2NPT" 22037905D 1
11 PLUG; HEX; 1 1/2NPT" 22037905H 1
12 O RING-62.5x55.5x3.5 010451120 1
13 NIPPLE; PIPE; 1 1/2NPTX100" 22047674D 1
14 TANK,RECEIVER,ASME SEC VIII 030356150 1
MINIMUM PRESSURE VALVE 1 220210370 1
15
1/2",Release"
16 AIR OIL SEPARATOR ASSY 400CFM B674601 1
17 COVER, REC TANK 010452270 1
18 BOLT HEX M12X40 8.8 ZYP 5-8M 000906185 14
19 FLANGE COVER 1.5 INCH 035400036 1
20 FLANGE With PIPE 1.5 INCH 035400037 1
21 O RING SERVICE MANIFOLD NEW300 220472600 1
22 WASHER SPRING REC SEC M8 000996108 8
23 WASHER PLAIN M8 ZYP 000996008 4
24 BOLT HEX M8X30 8.8 ZYP 5-8M 000906117 4
25 PIPE COUPLING STYLE 12 1 1/2'' B56XX07 1
26 MANIFOLD AIROUTLET 030356140 1
27 BOLT HEX M8X20 8.8 ZYP 5-8M 000906115 4
28 GLASS, OIL SIGHT, 1 1/2NPT" 22041311A 1
29 TUBE BUNDY IS8119 6.35OD 0.71T 004701902 1
30 COUPLING; TMS; 1/4X1/4"NPT" 22047683A 1
31 HOSE ADAP.90DEG1/4NPTX1/4"BSP" 000959083 2
32 HOSE ASSY; 1/4X1100MM" 22037908C 1
33 BUSH; REDU; ADAP; 1/8X1/4"NPT" 22037901A 1
34 NIPPLE;HALF;HEX.REDU1/2"X70 010460720 1
35 ELBOW; TMS; 1/2"X1/2"NPT 22047681F 1
36 VALVE ASSY PR.RELIEF 1",Release" 010451240 1
37 SILENCER; BLOWDOWN; 1/2NPT" 220463010 1
38 PIPE MPV TO MANIFOLD 030356110 1
39 VALVE ASSY BD/SD 1/2NPT E10EP" 220460450 1
40 3/4"NPT 15 FCS BVS B312702 1
41 NIPPLE; PIPE; 3/4X50" 22047671A 1
42 3/4"NPT 15 FCS BVS B312702 3
43 VALVE; BALL; 1 1/2NPT" 220416400 1
44 VALVE GATE ¾” NPT 22041354A 1
45 FLANGE DCV 035400186 1
46 ORING - VITON 035400187 2
47* ADAPTER - HOSE 035400185 1
9
 SCREW AIR COMPRESSOR

1.4 COOLING SYSTEM

• Refer the figures given in the following pages.

• The cooling and lubrication system consists of mainly cooling fan mounted on the
Engine, shroud, oil cooler, oil filter and thermal valve.

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

• The thermal valve is fully closed when the oil temperature is 125°F.

• As the discharge temperature rises above 125°F due to the heat of compressor,
the oil temperature rises and the thermal valve begins to close the oil line from
tank to airend through oil filter to divert the oil through oil cooler. Depending on
the oil temperature, the thermal valve opening position ensures oil inlet
temperature to airend is maintained by,

a) Fully allowing oil from tank to airend

b) Fully allowing oil from cooler to airend
c) Mix of oil from tank and cooler to airend

• During starting of the machine the oil temperature and pressure are low. The oil
separated from 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 pressure differential through the oil cooler, main oil filter to the
AIREND in large quantities i.e. from the high pressure region in receiver tank to
the low pressure region in airend. The return line is operated throughout the
whole process.

• The Oil cooler removes the heat of compression from the oil.

• Now the oil after being cooled 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 or when the viscosity of the oil is too
high for adequate flow, which requires changing of filter element.

• After the oil is properly filtered, it flows to the compressor unit where it cools the
seals and the compression chamber as well as lubricating the bearings and
gears.

10
 SCREW AIR COMPRESSOR

COOLING SYSTEM

11
 SCREW AIR COMPRESSOR

COOLING SYSTEM

SL NO. DESCRIPTION PART CODE QTY.

1 RADIATOR & OIL COOLER B0078XXXX0001 1
2 PLUG , HEX. ¼” 22037905B 4
3 PLUG , HEX. SOCKET ¼” 22041038B 1
4 BRACKET ROC 030346510 1
5 BRACKET ROC 030346510 1
6 BOLT HEX. M8 X 20 LG 000906115 36
7 WASHER PLAIN , M8 000996008 44
8 NUT HEX M8 000948008 24
9 SHROUD, COOLING FAN 030346490 1
10 BRACKET, ROC SUPPORT 030446720 2
11 WASHER SPRING , M8 000996108 12
12 BOLT HEX. M8 X 30 LG 000906117 8
13 MTG, ANTI VIBRATION 22037506A 2
14 ANTI VIB MOUNT B001401110006 2
15 WASHER PLAIN, M12 000996012 6
16 WASHER SPRING, M12 000996112 6
17 BOLT HEX M12 X 30 LG 000906183 6
18 NUT HEX. M12 000948012 4

12
 15,16,17
25
22 14
1
24 12
22 13
1
13

11 8 4,5
20
12 19 18
26
9 7

4,5
10
1
3

2 4,5,6

1
Base Part
LUBRICATION SYSTEM

SCREW AIR COMPRESSOR

 SCREW AIR COMPRESSOR

1.5 LUBRICATION SYSTEM

SL.NO DESCRIPTION PART CODE QTY

1 O RING ID 37.5x43.5x3 035400026 6
2 PIPE TANK TO MANIFOLD 035300408 1
3 MANIFOLD BLOCK 1 1/4 INCH 035300030 1
4 BOLT HEX M8X25 8.8 ZYP 5-8M 000906116 18
5 WASHER SPRING REC SEC M8 000996108 22
6 WASHER PLAIN M8 ZYP 000996008 1
7 HOSE OC TO MANIFOLD ONE INCH 035300179 1
8 HOSE MANIFOLD TO OC ONE INCH 035300178 1
9 ELEMENT, THERM VALVE 125 DEG 220310800 1
10 O RING ID 37.5x43.5x3 035400026 1
11 HOSE MANIFOLD TO MOF 035300370 1
12 HOSE ADAPTER11/4 " 220370770 1
13 OIL FILTER 10 MICRON RATING 010440220 1
14 BRACKET MOF MOUNTING 035300048 1
15 WASHER PLAIN M10 ZYP 000996010 2
16 WASHER SPRING REC SEC M10 000996110 2
17 BOLT HEX M10X30 8.8 ZYP 5-8M 000906145 2
18 NIPPLE; HEX; 1 1/4NPT" 22037903F 1
19 ELBOW; PIPE; 90'; 1 1/4NPT" 22047677F 1
20 ADAPTER WITH FLANGE 1-1/4 035400024 1
21 O RING ID60x3DIA 030449650 2
22 PIPE WITH FLANGE 1-1/2 035400025 2
23 BOLT HEX M8X30 8.8 ZYP 5-8M 000906117 4
24 VALVE ASSY, OIL STOP,1 1/2NPT" 22031032A 1
25 PIPE FILTER TO AIREND 035300035 1
26 ORIFICE OIL INJECTION ADAPTER 035400016 1
27 ELBOW; TMS; 1 1/4"X1 1/4"NPT 22047681J 1

14
 SCREW AIR COMPRESSOR

2,3,4

Supplied With Base

BASE SYSTEM

1.6 BASE SYSTEM

SL.NO DESCRIPTION PART CODE QTY

1 TROLLEY 035300049 1
2 BOLT HEX M16X30 8.8 ZYP 5-8M 000906212 4
3 WASHER SPRING REC SEC M16 000996116 4
4 WASHER PLAIN M16 000996016 4

15
 9

15
12,13
7
11 4 6
17 12,13
16

10

4 2 14
3
8
10

SCREW AIR COMPRESSOR

19 1
18
20 CANOPY SYSTEM
 SCREW AIR COMPRESSOR

1.7 CANOPY SYSTEM

SL NO. DESCRIPTION PART CODE QTY.

1 PANEL FRONT LH 035300050 1
2 DOOR LH 035300051 1
3 BOTTOM PANEL LH 035300078 1
4 PANEL REAR LH & RH 000996008 2
5 REAR COVER ROC 030394020 1
6 BOTTOM PANEL RH 035300079 1
7 PANEL FRONT RH 035300053 1
8 PANEL FRONT 035300054 1
9 TOP PANEL 035300055 1
10 MUD GUARD LH & RH 030396270 2
SUPPLIED WITH
11 STAINLESS STEEL HINGE 6
CANOPY
12 STAY ROD 035400021 2
13 STAY ROD PIN 035400022 4
14 REAR COVER ELECTRICAL PANEL 035300056 1
15 DOOR RH 035300062 1
16 REAR COVER PANEL BOARD ENGINE 030395030 1
SCREW SOCKET COUNTER SUNK SUPPLIED WITH
17 24
HEAD M8 X 25 CANOPY
18 SPRING WASHER M8 000986108 104
19 HEX. BOLT M8 X 20, ZYP 000906115 80
20 WASHER PLAIN M8 000996008 80

17
 SCREW AIR COMPRESSOR

ENGINE SYSTEM

18
 SCREW AIR COMPRESSOR

1.8 ENGINE SYSTEM

Sl.No. Description Part Code Qty.

1 Engine, 4BT , 3.9 C B958902 1
2 Adapter Ring 030346470 1
3 Drive Coupling B005400900006 1
4 Bolt,Hex 3/8” UNC 000907227 8
5 Washer , Spring Rec , 3/8” UNC 000996203 8
6 Bolt Hex M10 x 30 000906145 22
7 Washer Spring, ZYP , M10 000996110 28
8 Washer Plain , ZYP , M10 000996010 28
9 Bolt Hex M10 x 35 000906146 6
10 Bracket , Engine Air Filter Mounting 030346450 1
11 Hex. Bolt M 12 x 20 lg, ZYP 000906181 6
12 Plain Washer , ZYP , M12 000996012 4
13 Bolt, Hex M10 x 25 , ZYP 000906144 4
14 Nut, M10 , ZYP 000948010 4
15 Tank, Diesel 114 litres 030346650 1
16 Bolt, Hex, M8 x 20 , ZYP 000906115 12
17 Spring, washer M8, ZYP 000996108 12
18 Washer, Plain M8, ZYP 000996008 22
19 Plug, Hex ½” NPT 22037905 D 1
20 Breather , Assembly 220472590 1
21 Cap , Fuel Tank 220420320 1
22 Filter Nipple, TRC 2000 000470340 1
23 Pipe with flange fuel line 030446690 1
24 SCR SOC HD M6 x 20 000983064 4
25 Washer , Plain M6 000996006 4
26 Gasket, Diesel Tank 030447320 1
27 Anti Vibration Mount B141420 2
28 Bolt Hex M12 x 30 000906183 4
29 Spring Washer, M12 , ZYP 000996112 8
30 Anti Vibration Mount B141419 2
31 Bolt Hex M16 x 30 , ZYP 000906212 4
32 Washer , Spring M16 Rec ZYP 000996116 4
33 Washer Plain M16 , ZYP 000996016 4
19
 SCREW AIR COMPRESSOR

34 Washer, Spring M20, ZYP 000996120 2

35 Bolt Hex M20 x 40 , ZYP 000906241 2
Sl.No. Description Part Code Qty.
36 Band, Exhaust Pipe Mounting 030446780 1
37 Bolt Hex M8 x 35 , ZYP 000906118 6
38 Nut M8 , ZYP 000948008 11
39 Band, Silencer Mounting 030446770 2
40 Duct, Silencer Outlet 030446760 1
41 Duct , final exhaust 030346530 1
42 Fuel Level Indicator B0107XXXX0001 1
43 Bolt Hex M5 x 20 000906056 6
44 Connector 2
45 Adapter Breather 030447300 1

20
 SCREW AIR COMPRESSOR

1.9 CAPACITY CONTROL SYSTEM

• The functional description of the capacity control system is described below in 2 distinct phases
of operation. This description will apply to all control system with an exception to the pressure set
according to your pressure requirements, which can be achieved by adjusting the pressure
regulator
• The control system for the set pressures will be in accordance with a machine’s operating
pressure
• A typical control system is illustrated in the figure

1.9.1 START

When the compressor is started, the atmospheric air is drawn through the Butterfly valve,
compressed and discharged to the air/oil receiver. The pressure builds up in the receiver tank
2
from 0 to 4 kgf/cm . During this period the pressure regulator valve and the actuator are
inoperative. The Butterfly valve is open and compressor operates at full rated capacity. As the
compressor operates at full capacity, the engine runs at rated speed. The rising receiver tank
pressure is isolated from the service line by the minimum pressure valve, which is set at 4
2
kgf/cm .

1.9.2 NORMAL OPERATION

When the receiver tank pressure rises above 4 kgf/cm2, the minimum pressure valve opens
and delivers compressed air to the service line. At this time, the actuator remains inoperative,
holding the intake valve fully open for maximum air output. The engine will continue to run at
rated speed during this phase of operation.

1.9.3 MODULATION

In case of air being used is less than the rated capacity of the compressor, the service line
pressure will rise above operating pressure. Now the pressure regulator valve gradually opens,
applying pressure to the actuator and Butterfly valve. This causes the actuator to reduce the
speed of the engine . As the pressure increases, the actuator will further close and reduce the
engine speed until it reaches loaded speed, and closing the Butterfly valve.

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
matching the air demand. The orifice also bleeds any accumulated moisture from the actuator.
The compressor will continue to run in this manner until air demand increases. As air demand
increases, the receiver tank pressure will fall to operating pressure. The pressure regulator valve
will close; the air intake valve will be fully open and the engine will once again run at rated
speed.

1.9.4 SHUT DOWN

The blowdown valve is normally closed type, the pulse line taken from the suction end of the
airend will keep the blow down valve in normally closed condition during running. Upon shut down
the pressure signal will act leading the blowdown valve to open and venting the receiver tank
pressure to the atmosphere.

21
 SCREW AIR COMPRESSOR

R01 – DOUBLE ACTUATOR IMPLEMENTED FROM 08/2007

22
 SCREW AIR COMPRESSOR

CONTROL SYSTEM

SL NO Description Part Code Qty.

1 VALVE ASSY, PR. RELIEF 1” A010107 1
2 ELBOW ,TMS ½” X ½” 22047681F 1
3 NIPPLE HALF HEX REDU ½”x70 010460720 1
4 BLOW DOWN VALVE ½” A010029 1
5 BOLT , HEX M8 X 30 LONG 000906117 1
6 SILENCER, BLOWDOWN , ½” NPT 220463010 1
7 NIPPLE, HEX ½”NPT 22037903C 1
8 NIPPLE, HEX ¼” NPT 22037903A 3
9 TEE, PIPE , ¼”NPT 22047680A 5
10 ADAPTER HOSE, ¼”BSP X ¼” NPT 220370680 6
11 VALVE ASSY, PR REG, ¼” NPT 220317590 1
12 ORIFICE , CONTROL, 1/8” X ¼” NPT 22041731A 2
13 MUFFLER, AIR EJECTOR, 1/8” NPT 22041355A 2
14 WASHER PLAIN M16 000996016 2
15 HOSE, ¼” X 750 MM LONG 22037908A 2
16 HOSE, ¼” X 1000 MM LONG 22037908B 1
17 HOSE, ¼” X 750 MM LONG 22037908A 1
18 HOSE, ¼” X 450 MM LONG 22037908H 1
19 ACTUATOR, ASSY , SINGLE ACTING A030006 2
20 BOLT, PIN ACTUATOR 030449200 1
21 ROD END BEARING B495201 1
22 FIP LEVER ACTUATOR 035400189 1
23 PIN ACTUATOR DPSAC 220473650 2
24 BRACKET, ACTUATOR MOUNTING 030346630 1
25 BOLT , HEX M8 X 30 LONG 000906117 5
26 WASHER SPRING, REC SEC M8, ZYP 000996108 6
27 WASHER PLAIN, M8 ZYP 000996008 6
28 NUT HEX M8 , ZYP 000948008 4
29 NUT HEX M10 000948010 2
30 WASHER SPRING REC SEC M10 000996110 4
31 WASHER SPRING REC SEC M6 000996106 2
32 BOLT HEX M6 X 35 ZYP 000906089 2
33 MOISTURE WITH DRAIN ¼” B442501 1
34 HEX NUT M6 000948007 2
35 BKT MTG PRESS REGULATOR 220471970 1
36 PLATE ACTUATOR 16S 220473630 1
37 LEVER INLET 22047366A 1
38 M12 NYLOC NUT 000928312 1
39 ACTUATOR MOUNTING BRACKET 035400188 1

23
 SCREW AIR COMPRESSOR

1.10 ELGI AIR LUBE

Oil performs a very critical function in the oil flooded screw type air compressor. This
takes away major part of the heat of the compression, seals all the areas and lubricates
bearings and gears. The major criteria in a good quality lubricant for screw compressor
are

a) Viscosity
b) Wear characteristic
c) Demalcibility
d) Heat resistance
e) Thermal stability

Elgi Airlube is blended using heavy-duty hydraulic based oil with proper amount of
additives and strict quality control check of every batch footprint ensures satisfactory
compressor performance.
0
Life of mineral oil is covered by operating temperature for every 10 C of temperature
0
beyond 95 C. Life of oil goes down by almost 30-40%. It is recommended that oil change
frequency could be vary between summer months and winter months to get best out of
the mineral oil and compressor. For this, a good record of operating temperature of
compressor is essential. Continuous operating of compressor at high temperature
0
beyond 100 C without changing the oil will lead to varnish formation and will affect the life
of bearings and air end.

PROPOSED DRAIN PEROID

Sl.No. Description Drain Period

Normal industrial application with max operating
1. 1000 hours
temperature 95 deg C

2. Industrial application with dusty environment 750 hours

Engine driven compressor used for Water well drilling

3. and mining up to 200 PSIG - operating temperature 95 500 hours
deg C and below
Rig Compressors used for Waterwell drilling and mining
4. beyond 200 PSIG - operating temperature beyond 95 400 hours
deg C

All the above figures are guidelines 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.

24
 SCREW AIR COMPRESSOR

2.0 ELECTRICAL SYSTEM AND CONTROL ELEMENTS

2.1 SYSTEM COMPONENTS & DESCRIPTION
The electrical system comprises of not only necessary equipment to operate the
compressor, but also a system is 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, two batteries , an alternator with built-in voltage regulator.

The Electrical control system comprises of:

1. 24 Volt battery
2. Battery charge Indicator
3. Alternator with built-in voltage regulator
4. Ignition/ Override switch
5. Engine stop – Toggle Switch
6. Start push button
7. Engine starter with integral solenoid
8. Hour meter
9. Indicating lamps
10.
2.2 INSTRUMENT PANEL

Instrument panel consists of line pressure gauge, discharge temperature gauge, engine
water temperature gauge, engine oil pressure gauge, start button, override key, engine
stop – Toggle switch, tach-hour meter, indicating lamp.

The functional locations of the following controls are as follows.

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 air end.

Engine oil pressure gauge monitors engine lub oil pressure.

Engine water temperature gauge monitors the temperature of the cooling water.

The Battery charge indicator indicates the performance of the electrical charging
system.

Engine stop – Toggle switch when switched off , puts off the engine.

Start Button: Press button to start the engine. Release immediately when engine fires.

Override Key: Turnkey to check all electrical connection. Further turn to override all
switches.

Tachometer/ Hour Meter: Tachometer indicates the engine speed and Hour Meter
indicates accumulated hours of compressor operation. This is useful for planning and
logging service operation.
25
 SCREW AIR COMPRESSOR

WIRING CIRCUIT DIAGRAM

01

300/100 4BT 24 VOLTS

ELEC.SYSTEM
03
8 3
6000
8

26
 SCREW AIR COMPRESSOR

2.3 PURPOSE OF CONTROLS

No. CONTROL OR INDICATOR PURPOSE

01. Start push button* Press to start the engine. Release
immediately when engine fires.

02. Engine stop – Toggle switch* Switch off the toggle switch to stop the
engine.

03. Override key* Turn key to check all electrical connection.

Further turn to override all switches. Release
the key once engine starts.
04. Engine oil pressure gauge Monitors engine oil pressure. Normal reading
2
is 3-4 kgf/cm at rated RPM.

05. Engine water temperature gauge Monitors the temperature of the engine water.
Normal operating temperature is 70-90 deg C.

06. Discharge temperature gauge Monitors temperature of air/oil mixture leaving

the compressor unit.

07. Oil sight glass Monitors oil level in the Receiver Tank.
Check oil level only when machine is shut
down.
2
08. Minimum pressure valve Maintains minimum pressure of 3-4 kgf/cm in
the receiver tank. This valve restricts receiver
air discharge from receiver tank to the service
2
line when pressure falls below 3 - 4 kgf/cm .
However full flow is allowed at normal
operating pressure.
09. Single acting actuator Regulates the speed of the engine.
This regulation is determined by the amount
of air being used at the service line.

10. Pressure regulator valve Opens a pressure line between the receiver
tank and actuator allowing actuator to regulate
engine speed according to air demand.

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

NOTE:- Controls having “ * ” symbol are subject to availablity in particular models.

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 SCREW AIR COMPRESSOR

INSTRUMENT SYSTEM

INSTRUMENT SYSTEM

SL No. Description Part Code Qty.

1 Pressure Gauge 010460660 1
2 Discharge Temperature gauge B202101 1
3 MCB DP 40A 008927029 1
4 Panel Board 035300315 1
5 Key, Switch Engine Scope 1
6 Selector Switch;2p&1no 008940060 1

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 SCREW AIR COMPRESSOR

3.0 RECOMMENDED SPARES

Kit of spares after completion of 2500

Part Code Qty
hours of running, contains

Air filter kit 220419480 2 sets.

Oil filter kit 010440229 6 nos.
Elgi air lube oil 000998043 144 lt.
Gasket, butterfly valve 4” 220412000 2 nos.
Separator element B674601 2 nos.
Kit, valve, minimum pressure 1½ " NPT 220210379 1 no.
Kit actuator, single acting 220465029 1 no.
1/4
Kit valve, pressure regulator 1 " NPT 220317599 1 no.
Kit, oil stop 1 ½” 220310329 1 no.
Kit, valve, blow down valve ½” 220371089 1 no.

Spare after completion of 10000 hours

Part Code Qty
of running,

ELEMENT COUPLING S2800 GR1911 B005400900009 1

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