TS - 03 - 05 - 07 - 10 - 15 - HN - TS10 - HT

Do’s and Dont’s
Dos
! Read the manual in detail and follow the instructions.
! Clean the air compressor package regularly.
! Keep the air filter clean.
! Use only genuine spares.
! Maintain correct oil level.
! Use only clean, recommended lubricants.
! Use proper tools.
! Attend immediately to anything unusual with the air

compressor.
! Maintain log book to monitor operation of compressor.
! Attend Repairs / Service with qualified technicians only.
Dont’s
" Neglect the 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 eventhough it

is of continuous rating.
1
Safety instructions
Never touch moving parts
Never place your hands, fingers or other body parts near the
compressor’s moving parts.
Never operate without all guards in place

Never operate this compressor without all guards or safety features in
place and in proper working order. If maintenance or servicing requires
the removal of a guard or safety features, be sure to replace the guards
or safety feature before resuming operation of the compressor.
Always wear eye protection
Always wear safety goggles or equivalent eye protection. Compressed

air must never be aimed at anyone or any part of the body.
Protect yourself against hot spot
Prevent body contact with grounded surfaces such as pipes, cylinders,

cylinder heads and motor. Never operate the compressor in damp or wet
locations.
Disconnect the compressor
Always disconnect the compressor from the power source and remove
the compressed air from the air tank before servicing, inspecting,
maintaining, cleaning, replacing or checking any parts.
Avoid unintentional starting
Do not carry the compressor while it is connected to its power source

or when the air tank is filled with compressed air.
Store compressor properly
When not in use, the compressor should be stored in dry place, remove
the electrical supply. Keep out of reach of children. Lock – out the
storage area.
Keep work area clean
Cluttered areas invite injures. Clear all work areas of unnecessary tools,
debris, furniture etc.
Keep children away
Do not let visitors contact compressor extension cord. All visitors should
be kept safely away from work area.
2
Safety instructions
Operate compressor at the rated voltage
Operate the compressor at voltages specified on their nameplates. If

using the compressor at a higher voltage than the rated voltage, it will
result in abnormally fast motor revolution and may damage the unit and
burn out the motor.
Never use a compressor which is defective or

operating abnormally
If the compressor appears to be operating unusually, making strange

noises, or otherwise appears defective, stop using it immediately and
arrange for repairs by a authorized service center.
Use only genuine replacement parts
Replacement parts not original may void your warranty and can lead to
malfunction and resulting injuries. Genuine parts are available from
your dealer.
Do not modify the compressor
Do not modify the compressor. Always contact the authorized service

center for any repairs. Unauthorized modification may not only impair the
compressor performance but may also result in accident or injury to
repair personnel who do not have the required knowledge and technical
expertise to perform the repair operations correctly.
Turn off the starter stop button to be latched

when the compressor is not used
When the compressor is not used, disconnect it from the power source
and open the drain cock to discharge the compressed air from the air tank.
Drain tank
Drain tank daily or after 4 hours of use. Open drain fitting and tilt
compressor to empty accumulated water.
Dress properly
Do not wear loose clothing or jewellery. They can be caught in moving
parts. Wear protective hair covering to contain long hair.
Maintain compressor with care
Follow instructions for lubricating. Inspect cords periodically and if

damaged, have repaired by authorized service facility. Inspect extension
cords periodically and replace if damaged.
3
Safety instructions
Before further use of the compressor, a guard or other part is damaged

should be carefully checked to determine that it will operate properly and
perform its intended function.
Check for alignment of moving parts, binding of moving parts breakage

of parts, mounting, air leak, and any other conditions that may affect
its operation.
A guard or other part that is damaged should be properly repaired or

replaced by an authorized service centre unless otherwise indicated
elsewhere in this Instruction Manual. Have defective pressure switches
replaced by authorized service centre. Do not use compressor if switch
does not turn it on and off.
Handle compressor correctly
Operate the compressor according to the instructions provided herein.

Never allow the compressor to be operated by children, individuals
unfamiliar with its operator or unauthorized personnel.
Keep all screws, bolts and cover tightly in place
Keep all screws, bolts and plates tightly mounted. Electrical

connections to be ensured for tightness. Check their conditions
periodically.
Keep motor air vent clean
The motor air vent must be kept clean so that air can freely flow at all
times. Check for dust build-up frequently.
Electrical installation
This compressor motor and starter should properly grounded with correct
size copper wire to avoid electrical shock and damage to the equipment.
The correct rating of fuses to be provided at the incoming side of the

Starter
The correct rating of wires to be used for incoming connection and

length of the cable to be less than 5 mtrs.
Never take any loop lines from the compressor wiring.
WARNING
Avoid electrical shock hazard. Never use this
compressor with a damaged or frayed electrical cord
or extension cord. Inspect all electrical cords regularly.
Never use in near water or in any environment where
electric shock is possible.
4
Technical Specifications
01 Model TS 03 120 HN
02 Type Reciprocating, Air cooled, Splash lubricated
03 Displacement m3/h 18.16
lpm 302.74
cfm 10.69
04 Free air delivery @ 10 bar m3/h 15.00
lpm 249.95
cfm 8.82
05 Working pressure kgf/cm2 12
06 Type of configuration V
07 Compression stages No. 2
08 Cylinders No. 2
09 Cylinder size & stroke mm 70 x 50 x 85
10 Type of piston rings Dia 70 Dia 50

a) Plain compression No. 1 1
b) Stepped compression No. 1 1
c) Slotted oil control No. 2 2
11 Clearance between piston mm 0.95 to 1.35
crown and cylinder top
12 Type of valve Finger
13 Volumetric efficiency % 78
14 Compressor speed rpm 925
15 Motor type Sq. cage Ind. TEFC
16 Motor rating HP 3
kW 2.2
17 Motor speed - syn. rpm 1420
18 Motor frame size 100 L
5
19 Degree of protection IP55
20 Class of insulation F
21 Electric supply
a) Voltage V 415 / 380

b) Phase 3
c) Frequency Hz 50
22 Type of starter DOL
23 Belt size & qty 160 / 220 ltrs A 70x2 / A 74x2
24 Specific power consumption kW/m3/h 0.1366
25 Type of lubrication Splash
26 Type of cooling Air
27 Type of fan Forced draught
28 Oil fill capacity ml 580max 440 min.
29 Grade of oil (Servo Press)

a) -15 to +80 deg C ELGI AIRLUBE
30 Outlet air temperature Deg C 10 above ambient
31 Air outlet size BSP 1/2’’
32 Pressure switch set pressure

a) cut off kgf/cm2 12
b) cut in kgf/cm2 9
33 Safety valve set pressure

a) Intercooler kgf/cm2 6
b) Aftercooler kgf/cm2 16.2
c) Air receiver kgf/cm2 14
34 Air receiver capacity litre 160 220
35 Overall dimensions mm 1345 x 510 1595 x 510

(lxbxh) x 1085 x 1085
36 Nett weight Kg 200 225
6
01 Model TS 05 120 HN 220/420 ltrs
03 Displacement m3/h 30
lpm 501.27
cfm 17.7
lpm 409.79
cfm 14.47
08 Cylinders No. 2

kW 3.7
18 Motor frame size 112 M
7
21 Electric supply

b) Phase 3
c) Frequency Hz 50
23 Belt size & qty B 74 x 2


b) cut in kgf/cm2 9
34 Air receiver capacity litre 220 420 ltrs
35 Overall dimensions mm 1595 x 585 1680 x 665

(lxbxh) x 1095 x 1250
36 Nett weight Kg 200
8
01 Model TS 07 120 HN - 220/500 Ltrs
03 Displacement m3/h 42
lpm 700.93
cfm 24.75
lpm 584.82
cfm 20.65
08 Cylinders No. 2

16 Motor rating HP 7.5
kW 5.5
18 Motor frame size 132 S
9
21 Electric supply
a) Voltage V 380/400/415
b) Phase 3
c) Frequency Hz 50
23 Belt size & qty 220/500 ltrs B74x2 / B76x2
28 Oil fill capacity ml 750 max 480 min.


b) cut in kgf/cm2 9
34 Air receiver capacity litre 220/500 Ltrs
35 Overall dimensions WE WOE

(lxbxh) mm 220 L 1600x630x1120 1600x590x1120
500 L 1900x895x1350 1900x745x1350
10
01 Model TS 10 120 HN 220/420/500 Ltrs
lpm 1001.98
cfm 35.38
lpm 852.98
cfm 30.119
06 Type of configuration W
08 Cylinders No. 3
09 Cylinder size & stroke mm 100 x 70 x 100 x 85

kW 7.5
11
20 Class of insulation B
21 Electric supply

b) Phase 3
c) Frequency Hz 50
23 Belt size & qty 220/420/500L B76 x 2, B78 x 2


b) cut in kgf/cm 2
9
b) Aftercooler kgf/cm2 16
c) Air receiver kgf/cm 2
14
34 Air receiver capacity litre 220L / 420L / 500L
WE WOE
35 Overall dimensions
(lxbxh) mm 220 L 1595x810x1205 1595x680x1205
420 L 1675x885x1350 1675x745x1350
500 L 1925x885x1350 1925x745x1350
36 Nett weight Kg -- --
12
01 Model TS 15 120 HN 420 & 500 Ltrs
lpm 1537.24
cfm 54.28
lpm 1249.78
cfm 44.13
06 Type of configuration W
08 Cylinders No. 3
09 Cylinder size & stroke mm 100 x 70 x 100 x 85

11 Clearance between piston mm LP - 0.20 / 0.60
crown and cylinder top HP - 0.95 / 1.35
12 Type of valve Combined disc
kW 11
13
21 Electric supply

b) Phase 3
c) Frequency Hz 50
22 Type of starter STAR DELTA
23 Belt size & qty C 80 x 2


b) cut in kgf/cm2 9
b) Aftercooler kgf/cm 2
16
c) Air receiver kgf/cm 2
14
34 Air receiver capacity litre 420 L/500 L
WE WOE
1675x885x1350 1675x745x1350
(lxbxh) mm
1925x885x1350 1925x745x1350
36 Nett weight Kg -- --
14
01 Model TS 10 HT (Twin cylinder)
lpm 996.884
cfm 35.2
lpm 849.61
cfm 30
08 Cylinders No. 2

c) Ring oil Exp No. 1 1

2 2
d) Ring oil Seg No.
11 Clearance between piston mm LP 0.2 to 0.6

crown and cylinder top HP 0.9 to 1.35
12 Type of valve LP Reed valve

HP Finger
kW 7.5
15
21 Electric supply
a) Voltage V 415
b) Phase Ph 3
c) Frequency Hz 50
23 Belt size & qty B 104 x 2

@ 10kgf/cm2


b) cut in kgf/cm2 9
b) Aftercooler kgf/cm2 16
34 Air receiver capacity litre 420
WE WOE
(lxbxh) mm 1665x880x1315 1665x740x1315
16
System operation
The atmospheric air aspirated through the inlet air fiters is compressed in
the cylinders of the reciprocating air compressor driven by the prime mover.
Under normal conditions, the first stage compression end temperature

amounts to approximately 850 C. This compressed air enters into the inter
cooler, where the compression heat is considerably reduced. Inter cooler
has safety valve which opens when the compressed air pressure exceeds
the predetermined set pressure. Intercooler also houses a drain valve., used
to drain the accumulated moisture after shutdown of the machine.
This cooled compressed air then enters into the high pressure cylinder,
there it is further compressed to attain the specified pressure.
During the second stage of compression, the heat is further generated and
in normal condition, the compression end temperature amounts to
approximately 190oC. This compressed air passes through an after cooler
where the compression heat is dropped to a permissible level. At the end of
after cooler pipe, a safety valve is provided which opens when the
compressed air pressure in the after cooler, exceeds the predetermined set
pressure.
The cooled pressurised air passes through a non return valve into a
reservoir called air receiver / delivery pipe As the compressed air flows
continuously into the air receiver / delivery pipe, pressure gets built up in
the receiver / delivery pipe.
A safety valve is provided on the air receiver / delivery pipe to bleed the
excessive air pressure from the air receiver / delivery pipe whenever the
pressure switch fails to respond the pressure rise inside the air receiver
/ delivery pipe.
At one end of the air receiver / delivery pipe a ball valve is fitted to draw out
the compressed air to service line.
17
Product Representation
Tank mounted package model : TS 03 120 HN
18
Tank mounted package model : TS 10 120 HT
19
To atm
Atmospheric To Service
Air
No Description Qty
1. Inlet air filter 1
2. Compressor unit 1
3. Electric motor 1
4. After cooler 1
5. Safety valve (After cooler) 1
6. Non return valve 1
7. Pressure switch with unloader valve 1
8. Safety valve (Air receiver) 1
9. Pressure guage 1
10. Ball valve (Service) 1
11. Air receiver 1
12. Drain valve 1
20
No Description Qty
02. Compressed unit 1
03. Electric motor 1
04. After cooler 2
05 Safetyvalve (After cooler) 1
06. Non return Valve 1
07. Pressure switch with unloader valve 1
08. Safety Valve (Air receiver) 1
09. Pressure guage 1
10. Ball Valve (service) 1
11. Air receiver 1
12. Drain Valve 1
21
No Description Qty
02. Compressed unit 1
03. Electric motor 1
04. After cooler 2
05 Safetyvalve (After cooler) 1
06. DUV / Solenoid Valve 1
07. Silencer 1
08. Non return valve 1
09. Pressure guage 1
10 Safety valve ( air receiver) 1
11 Pressure Guage 1
12. Ball Valve (service) 1
13. Air receiver 1
14. Drain Valve 1
22
Functions of various systems
Reciprocating Air Compressor Unit
The Reciprocating air compressor unit converts the rotary motion into
reciprocating motion with the help of crankshaft and connecting rod
assembly. Due to the reciprocating motion, the air is sucked into the cyclinder,
compressed and the compressed air is delivered into the air receiver. In case
of L.P. cylinders combined disc valves perform suction and discharge
operations where as the stainless steel finger type valve plates platform the
opening closing of suction and discharge ports provided on the valve flat on
H.P. cylinder. An oil splasher is fitted to the connecting rod to lubricate all the
moving parts.
Crankcase
The crankcase is made of high grade cast iron an houses the crankshaft
assembly and cylinders. It act as the sump for lubricating oil and is provided
with a breather, drain plug and a dipstick assembly. The breather maintains a
partial vacuum in the crankcase to facilitate better lubrication.
Cylinder and Cylinder Head
The cylinders and cylinder heads are made of high grade cast iron and they
have close deep fins for effective cooling. The hardness of the cylinders is
closely controlled to ensure high wear resistance.
Connecting Rod and Crankshaft Assembly
The connecting rod and crankshaft assembly is precision machined and

dynamically balanced. The crankshaft and web are forged out of carbon steel,
hardened and precision ground. The crankshaft is provided with steel bearing
rollers and small ends are provided with phosper bronze bushes.
Piston and Piston Rings
The pistons are of automotive type made out of low expansion aluminium
alloy. They are provided with plain compression rings, stepped compression
rings and slotted oil control rings.The rings are made of special quality close
grained cast iron and designed for controlling wear and oil consumption
minimum. The gudgeon pins are of chrome steel case hardened and precision
ground.
23
Functions of various systems
Inter Cooler
The Intercooler consists of aluminium body with fins for effective cooling.
Prime Mover - Electric Motor
Electric motor provides the power required to drive the compressor.
Drive System
The drive system transmits the power required to drive the compressor from
the prime mover. The drive system comprises of a drive pully mounted on the
motor shaft and a driven pulley mounted on the crankshaft on the
compressor unit. The motion is transmitted between the pulleys through V
belts. A belt guard is provided on the side of the drive system ensures
protection of the operator.
The dynamically balanced driven pulley fitted on the crankshaft acts as a

flywheel which imparts vibration free dynamic rotation of the crankshaft. The
fan fitted on the driven pulley forces the air on the cylinders, cylinder heads,
after cooler which cools down the temperature of whole unit.
Electric Control
The electric motor is connected in series to the Direct online Starter. When
the starter is switched ON, the motor starts running. The electric power
supply to the motor is controlled by the pressure switch response to the air
pressure inside the air receiver /delivery pipe. Whenever the air pressure of
the air receiver / delivery pipe exceeds the pre-determined set valve, the
pressure switch cuts OFF the supply to the motor and whenever pressure
drops down to the set pressure, the pressure switch cuts IN the power
supply to the motor through starter.
Air Receiver
In tank mounted model, the air receiver is used to store the compressed air.
Whenever compressed air is required. The ball valve in the service line is
operated to draw the compressed air. All the elements / modules of the
compressor package is mounted on the air receiver.
24
Safety devices
Safety valve - After cooler
Vents excess air pressure to atmosphere built up in the after cooler

whenever pressure rises more than 130% of working pressure owing to any
malfunction of non-return valve.
Safety valve - Air receiver / Delivery pipe
Vents excess air pressure to atmosphere in the air receiver / delivery pipe in
the event of failure of pressure switch responding to the pressure rise above
the upper set limit of pressure switch (CUT OFF)
Delivery unloader valve
For above 15 H.P. model, the DUV vents the pressurised air from the after
cooler to atmosphere. When the air pulse from solenoid valve lifts the piston
in delivery unloader valve. (For below 10 H.P.models, the pressure switch
has unloading system).
Interlocking devices
Pressure Switch
If cuts OFF power supply to the motor whenever air pressure inside the air
receiver / delivery pipe exceeds the pre-determined set value and cuts ON
the power supply to the motor whenever the air pressure drops down to the
diffrential set value.
Non-return valve
Non-return valve is one way automatic, spring loaded shut off valve which
allows the compressed air into the air receiver / delivery pipe and prevents
the air from returning to the after cooler.
25
Electrical system
# The electrical circuit diagram is shown in Figure (Refer page no. 23 & 24).
# The compressor starter is basically a Star-delta Starter / Direct online

starter with safety interlock.
# The overload relay is set for equal to the motor name plate current for
star delta / DOL starter respectively.
# The tripped overload relay is reset by depressing the ‘Stop' button of the
starter.
# While the compressor is running, if it is desired to stop the compressor

momentarily, depress the stop button and latch it.
# On releasing the latch, the compressor will restart and run continuously
till the rated output pressure is attained.
# The starter is switched on and off through pressure switch.
# Recommended fuse and cable size. (Refer table given below)
Back fuse and incoming cable size details (415 V / 50 Hz)
H.P. (3 Ph) Back up fuse (HRC only) Cable size
2 10 4Cx.5 Sq.mmCu
3 16 4Cx1.5 Sq.mmCu
5 20 4Cx2.5 Sq.mmCu
7.5 25 4Cx2.5 Sq.mmCu
10 25 4Cx4 Sq.mmCu
12.5 32 4Cx4 Sq.mmCu
15 32 4Cx6 Sq.mmCu
NOTE
Power should be supplied to the compressor through a
fuse switch unit of suitable rating mounted within 5m of
the compressor
26
Electrical system
Main Supply
415V AC 50 Hz
L1 L2 L3
7
1 3 5
8 2 4 6
Contactor
Pressure Switch
98 96
O/L Relay
Stop / Reset / Trip
95 DOL Starter
A B C
Motor
Electric Circuit Diagram for DOL Starter
Star Delta Starter
Electric circuit diagram for star delts starter
27
Incoming Supply
415V 3Ph AC
L1 L2 L3
D1
A1 A2
On Delay
16 A1 A2
15 A1 A2
1 3 5 7 11 21 1 3 5 7
2 4 6 8 12 22 2 4 6 8
K3 K2
Delta main
23 24
98
Start 96
Stop Reset
A1 A2
1 3 5 7 11 21 95
2 4 6 8 12 22
K1
Star
28
Pressure Switch
Neutral
Solenoid Valve
A2 B2 C2 A1 B1 C1
To Motor To Motor
ELECTRIC CIRCUIT DIAGRAM FOR STAR DELTA STARTER

Electrical system
# Ensure that a separate main isolation switch is provided for every

individual compressor.
# Starter entry glands are fixed properly to avoid dust formation inside the
contactor points.
# Back up HRC fuse is arranged on the main switch.
# Main switch should be installed within a minimum 5 mtrs distance of the

compressor
# Incoming wire to the starter from the main switch shall be,
2.5 Sq.mm up to 10 HP
4 Sq.mm for 15 HP>
# Time duration between the two starts shall be a minimum of 6 minutes.
# Avoid the loop line connection from the out going line of the isolation
switch of compressor to any other motor / equipments.
# Avoid loose connection on all the points check from main electrical board,
isolation switch, starter entry, starter outlet and the compressor motor
terminals.
# Ensure the stabilization of system voltage to atleast 380 V, even during

starting.
# Chattering of starters while starting / running shall be recorded and the

reason for such chattering shall be identified.
# Ensure the thermal over load relay settings as per motor name plate,
which is rated full load current of the motor for the DOL starters.
The settings are set at the 0.58 times rated the full load current of the
motor for the Star - Delta Starters.
NOTE
Examine the package for transit damages Locate a
levelled ground in an airy room for compressor erection.
Leave 1000 mm space around the compressor for
adequate cooling and easy maintenance accessibility
29
Installation
Location of Compressor
The compressor package may be placed on any levelled surface capable of

supporting its weight. It is necessary to anchor the units as there is a
possibility of applied forces or vibration which could disturb the piping and
wiring.
WARNING
Never install the compressor near the boiler, furnace,
in an enclosed compartment or at any place where
the atmospheric air is hot and dirty.
Ventilation and Cooling
Select a location to permit sufficient unobstructed air flow in and out of the
compressor room to keep the operating temperature stable. The minimum
distance that the machine should be from surrounding walls is within working
limits. The machine should be installed at a minimum of 1000 mm from the
surrounding walls. It is imperative to provide adequate cross ventilation to
prevent excessive ambient temperature rise. Compressor room temperature
shall be limited to max 45O C.
Foundation
After selecting a suitable location, foundation shall be laid as per the detailed
drawing given below and then erect the compressor. The level of the
compressor must be checked by placing a spirit level on top of the air receiver/
base.
Tank mounted compressors of

TS 03 / 05 / 07 / 10 / 15 120 HN & TS 10 HT
For tank mounted compressor Section - XX
30
Installation
Foundation details
Description A B A' B'
160 Litres tank 800 330 1000 530
220 Litres tank 900 330 1100 530
250 Litres tank 1050 330 1250 530
420 Litres tank 1050 480 1250 680
500 Litres tank 1346 480 1550 680
Dimension on foundation of
TS 03 / 05 / 07 / 10 / 15 120 HN & TS 10 HT
NOTE
After anchoring the foundation bolts, ensure proper floor
level
Oil Level Check
Pour proper quantity of oil and check the oil level during installation. The
level is checked by looking at the oil level indicator provided on the
crankcase. If the oil level is low, add sufficient quantity of oil.
NOTE
Fill the lubricating oil into the crankcase through
breather hole after removing the breather from the end
cover.
31
Installation
WARNING
Before starting the unit, fill the crankcase with
correct grade and proper quantity of oil since the oil
is drained completely prior to shipping.
Max. Oil level
Min. Oil level
Oil Fill Capacity

TS 03 / 05 120 HN TS 07 120 HN TS 10 / 15 120 HN & 10 HT
Min : 440 ml Min : 480 ml Min : 770 ml
Max : 580 ml Max : 750 ml Max : 1150 ml
32
Installation
Belt Tension check
Ensure proper belt tension between the drive pulley (motor pulley) and driven
pulley (compressor pulley). If the belt tension is not correct, loosen the nut
lock and turn the tension adjusting bolt provided on the motor plate. On
completion of the adjustment, tighten the lock nut. When correctly adjusted,
the belt should have a play of 10 mm about their mean position.
WARNING
Too much belt tension will lead to excessive load
on the compressor and motor bearings.
Electrical preparation
Interior and other electrical wiring are carried out during the manufacturing
stage at factory itself. Nevertheless a thorough check up on the connections
if necessary to ensure a stage of trouble free first start up.
33
Installation
Care is taken to keep your Electrical work to the minimum possible. The
necessary electrical work should be done only by a qualified electrician. A
few electrical check should be made to help assure that first start up will be
trouble free.
a) Check the incoming voltage. Ensure that the incoming voltage is same as
that of the voltage that the machine is wired for.
b) Check all the electrical connections for tightness.
c) Connect the electrical power supply with correct rating of fuses. Avoid
loop lines from the compressor wiring points.
d) The compressor must be electrically earthed by connecting a copper wire

between the body of the compressor and earth.
e) 'DRY RUN' the electrical controls by disconnecting the motor leads from
the starter and energise it by releasing the stop button.
f) Jog the motor for direction of rotation check as described in figure

by reconnecting the motor leads.
34
Installation
Motor rotation check
After the electrical wiring has been done, it is necessary to check the
direction of the motor rotation. This can be done by jogging the stop button
on the Star-delta Starter. When looking at the oil level indication side of the
crankcase, the shaft should turn counter clockwise. If the crankcase is not
turning counter clockwise, disconnect the power to the starter and
exchange two of the three power input leads. i.e. red and blue then recheck
rotation.
Motor rotation check for model : TS 03/05/07/10/15 HN
Motor rotation check for model : TS 10 HT
Servicing air piping
A ball valve is installed in the compressor package to isolate the

compressor package from the service time. Also notice that the service line
is equipped with legs and condensate drains through out the service system
(not in Elgi's scope of supply).
35
Operation
General
While ELGI has built into compressor a comprehensive array of controls and
indicators to assure you that it is operating to full capability, you will want to
recognise and interpret the reading which will call for service or indicate the
beginning of a malfunction. Before starting your ELGI compressor, read this
section thoroughly and familiarize yourself with the controls and
indicators - their purpose, location and use.
Initial Start-up Procedure
# Read the preceeding pages thoroughly.
# Ensure all preparations and checks described in the chapter installation

have been taken care of.
# Fill the recommended grade of oil in the crankcase to the required level.
# Check that the compressor rotates freely by hand and there are no mechanical
obstructions.
# Check that the drain on the air receiver is closed.
# Open the shut off valve of service line slightly.
# Check all the points, mentioned in Electrical System.
WARNING
Before connecting the power supply to the
compressor, ensure the stop button in the starter
is latched.
# Connect the power to the unit.
# Jog the unit to check the direction of rotation.
# Run the compressor for a while and close the shut off valve. then carry
out a check on all adjustments given in clause 10 - 9 of maintenance
section of this manual.
# Open the shut off valve to service line.
# Re-inspect the machine for temperature and leaks, the following day.
36
Checks During Compressor Operation
# Check whether the compressor is running smoothly and that the running
sound is normal.
# The compressor crankcase and delivery pipe shall be hand-felt to ensure
that their temperatures are within touchable limits thoroughout the duration
of operation of the compressor.
# Observe for air leaks at the joints of the pipes and if noticed, stop the
compressor and rectify the defects.
Subsequent Start Up Procedure
On subsequent start up, check the proper oil level is visible in the dipstick
and simply release the latch in the starter.
To shut-off the machine, press the stop button.
WARNING
Do not touch the delivery parts of the compressor
since they are very hot. Touching may cause burns.
37
Operation
Purpose of Controls
S.
Control indicator Purpose
No
1. Stop push button Press to turn the compressor OFF.
2. Pressure gauge Continuously monitors air receiver/delivery

pipe pressure at various load and unload
conditions.
3. Oil level indicator Helps to keep a visual check on the oil level
in the crankcase. Check oil level only when
the machine is shut down. Do not overfill.
4. Safety valve-after cooler Set to open aftercooler air pressure to

atmospheric if pressure exceeds 130% of
the working pressure due to any
malfunction of Non-return valve.
5. Safety valve - Set to open excess air pressure (i.e. Air

air receiver/delivery pipe 130% of the working pressure) in the air
receiver / delivery pipe if there is any
malfunction / failure of the pressure switch
6. Non - return valve Allows the compressed air into the air
receiver/delivery pipe and prevents the air
receiver from returning to the after cooler.
7. Pressure switch Cuts OFF/ON power supply to the motor

in accordance with the air pressure
variation in the air reciever / delivery
pipe.
8. Unloading valve Unloads the air to the atmosphere from the

after cooler pipe whenever the unit is shut
down or in response to pressure switch
(Cuts OFF)
9. Breather Maintains partial vacuum inside the

crankcase to facilitate better lubrication
10. Drain valve Used to drain the condensate in the air

receiver.
11. Ball valve Isolate the compressor package from the

service line.
38
Maintenance
Follow the maintenance schedule described in this chapter for excellent

trouble free service
Frequency Maintenance Required Clause
Daily or before a) Check oil level

compressor b) Drain condensate water from air receiver a)
starting c) Check belt tension
150 hours or a) Releive moisture and dirt from air receiver b)

10 days b) Carry out first oil change
250 hours or a) Observe noise and vibration c)

20 days b) Check fasteners
c) Check air leaks
d) Check pressure setting
e) Check inlet air filter
Every 500 hours a) Change oil d)

or 1 month b) Check breather valve
c) Tighten all the wires
d) Clean the airfilter element
Every 1000 hours a) Inspect valves e)

or 3 months b) Check packings
c) Check NRV
d) Change filter element
e) Change breather valve
f) Check pressure setting
g) Check fasteners
Every 2500 hours a) Annual preventive maintenance with the f)

or 1 year tuneup kit Clean coolers
Every 2 years a) Clean and test air receiver g)

b) Change safety valves
Every 7500 hours

a) Overhaul the compressor h)
or 3 years
As you proceed in reading this chapter, it will be easy to see that the
maintenance programme of the unit is quite minimum but important.
39
Maintenance
a) First 24 hours or every day operation
# Relieve the compressor off dirt and dust.
# Check the oil level in the crankcase. Replenish with thecorrect grade if
required.
# Check the compressor belt tension.
# Drain condensate water from the air receiver.
b) First 150 hours or 10 days operation
# Dismantle the drain valve from air receiver and clean. Run the compressor
for some time without the drain valve to blow out all the moisture and dirt
from the air receiver.Reassemble the drain valve.
# During the oil change, the compressor should be run for a short while and
draining of the oil should be done only when the oil is warm.
NOTE
Carry out the first oil change after 150 hours of
operation and subsequent oil changes after every 500
hours of operation.
c) First 250 Hours or 20 days operation
# Check operational noise and vibration.

# Check tightness of mounting bolts and other fasteners.
# Check for air leaks in pressure line, after cooler, safety valves, drain
valves etc.
# Check pressure switch operation and ensure proper cut OFF and cut
IN pressures.
# Dismantle the inlet air filter, clean it with compressed air and reassemble
on the compressor.
40
Maintenance
d) Every 500 Hours or 1 month operation
# The breather valve should be dismantled, cleaned and checked for perfect
seating of the diaphragm and reassembled.
# Tighten all the wires in starter / Pr. switch / Motor
# Drain the oil and replenish with correct grade and quantity.
# Clean the airfilter element.
e) Every 1000 Hours or 3 months operation
# Remove the L.P cylinder heads. Dismantled the disc valves / Finger valves.
Decarbonise the valve discs, springs and valve plates.
# All the pipe lines should be checked for leaks at joints and replace packings
if necessary.
# Dismantle the non-return valve. Examine the spring for stiffness.Check

the valve seat. Replace the spring and valve seat if required.
# Change the filter element.
f) Every 2500 Hours or 1 year operation
# Decarbonize the after cooler pipe and the intercooler by any one of the
following methods:
a) Heat the cooler to appropriate temperature at which the carbon scaling

may disintegrate from the inside walls of the cooler. Then hammer the
after cooler with mallet to relieve the carbon particles off the after cooler.
b) Immerse the cooler in hydrocarbon like Benzene or Toluene solution for

a substantial period of time. Then clean the after cooler with compressed
air.
NOTE
Do not immerse the After cooler in Benzene or
Toluene solution for longer period of time, which will
result in damage to the After coolers.
41
Maintenance
Before dismantling the unit,
# Lubricate the electric motor bearings using a special grease gun or by

removing the end covers.
# The compressor should be completely stripped off by experienced

personnel. All parts have to be thoroughly cleaned, examined and repair
in a clean surrounding and rebuilt. Disconnect the power supply and release
all the air from the air receiver by opening the shut off valve and drain
valve. Pull the safety valves so that if there is many air left inside will
escape to atmosphere. Loosen the tension adjuster and remove the belts.
Remove the pipe connection. Open the drain plug and drain oil from the
crankcase.
# The permissible tightening torque values for threaded fasteners

of property are given in chart table.
NOTE
Replace a set of belts even if a single belt is found
worn out.
Thread size M6 M8 M10 M12

Tightening torque in kgf-m 0.47 1.2 2.3 6 4.2
(Max. permissible torque)
# Carryout the annual preventive maintenance with tune up kit through Elgi
authorised dealer.
g) Every two years of operation
STANDARD PROCEDURE FOR HYDRO TESTING OF RECEIVER

TANKS
# Fix the required dummy plugs in the sockets
# Connect the in line water hose pipe with ball valve assembly in the
receiver tank which is going to be tested
# Switch on the LP water pump and fill the Receiver tank(which is going
to be tested) with water. Lock the socket / Elbow, after the tank is
completely filled with water without air entrapment.
# Clean the weld area with air / dry cloth to remove water
42
Maintenance
# Pressurize the Tank (with Water) thro pump and maintain the hydro test
pressure as per drawing / below test conditions.
Check the receiver tank for any water leak in the weld area at the
following conditions
a) When the test pressure is reached
b) After 15 Minutes
c) After 30 Minutes
d) If any leak noticed, mark the leak area and rework accordingly.
e) Re-do the hydro test following above steps in case of any weld rework
f) If no leak noticed, connect the outline water hose pipe to the drain
valve and drain the water from the receiver tank by applying air pressure.
g) Record the test observations and rework (if any) and re-test observations
in a Test report and maintain in a file
Test conditions :
Test Parameter Specification
Hydro test Pressure Design Pressure * 1.43

(As per PED 97/23/EC – 1997 –
Clause 7.4 – Page 28)
Hydro Test Duration 30 Minutes
Hydro Test Temperature Ambient (20 deg C to 45 deg C)
Test Medium Water
Measuring Technique Calibrated Pressure Gauge
Sample Frequency 100% of tanks
Record the observation
h) Please contact the nearest authorised dealer of Elgi Equipments

Ltd., for compressor inspections and recommendation
43
Maintenance
NOTE
Users are advised to adhere to the requirements of
pressure test regulations of Government & Safety
Agencies, with respect to air receivers.
i) Pressure Switch
# The pressure switch operating pressures are adjusted at the factory and
do not require re-adjustments.
# However, if it is necessary to alter the factory settings. The pressure may

be increased or decreased within the limits indicated in the technical data
by the following simple procedure.
# The upper limits should never be exceeded. Figure given below for
Pr. adjustments.
j) Pressure Adjustment
# Remove the cover of the pressure switch
# Unlock and turn the control knob clockwise for increasing the cut off
pressure.
# Turn the control knob counter clockwise for decreasing the cut off pressure.
k) Diffrential Adjustment
# Depress the knob against the spring and turn clockwise for decreasing
the differential pressure i.e. to increase the cut pressure.
NOTE
It is necessery to keep the compressor Pressure switch
correctly adjusted as it is uneconomical to run the
compressor at higher pressure, if air pressure is
required is lower.
44
Maintenance
Pressure / Diffrential adjustments
45
Troubleshooting
Problem : Compressor overheats
Check Remedy
Dirty oil Change oil
Fill correct grade of oil upto maximum

Low oil level
level in the oil level indicator
Cylinder and Blow with compressed air or clean

aftercooler fins dirty manually
Breather valve not

Open, clean and refit after checking
working
Wrong direction of Interchange any of the two incoming

rotation terminal to the motor.
Problem : Compressor does not unload
Check Remedy
Blocked unloader pipes Open and clean
Open the pressure switch cover and

Defective unloader
adjust the nylock nut
46
Troubleshooting
Problem : Oil carry over in compressed air
Check Remedy
Chocked air filter Clean or renew the air filter element
Oil level high Drain to correct level.
Oil viscosity too low Change to recommended grade.
Breather not working Open, clean and refit after checking.
Loosen the piston rings, if broken change

Piston rings stuck
the rings as a set. Check all related parts
in grooves or broken
for wear before fitting.
Piston cylinder
Check and change as required.
clearance excessive
Problem : Water or rust formation in crankcase
Check Remedy
Check and replace the breather if

Faulty breather valve.
necessary.
47
Troubleshooting
Problem : Unusual wear of cylinder, piston and piston ring
Check Remedy
In adequate air filter

Increase frequency of cleaning.
maintenance.
Oil change frequency Increase frequency with more level in

insufficient. periodic check of oil.
Change to correct grade as given in

Incorrect grade of oil.
recommended lubricants chart.
Problem : Oil leak through breather valve

Check Remedy
Loosen the piston rings, if broken

Piston rings stuck in change the rings as a set. Check all
grooves or broken. related parts for wear before fitting.
Breather valve is not Open and refit the breather

working.
Piston to cylinder Check and change as required.

clearance excessive
Problem : Pressure switch does not work
Check Remedy
Puncture diaphragm
because of frequent Replace diaphragm and reset
operations (hunting) for pressure with more differential.
a very long time due to
very low differential.
48
Troubleshooting
Problem : Compressor knocking
Check Remedy
Remove fan pulley and examine

Loose compressor fan
keyway and key for wear.Change the
pulley.
key /pulley as required.
Worn out piston,

Overhaul compressor unit.
cylinder, crankshaft and
Replace the related components.
connecting rod bearings.
Check NRV and replace wornout

Valve seat of NRV worn
parts.
out.
Problem : Pressure built up time excessive
Check Remedy
Open and re-tighten with teflon tape or

Leak joints in pressure
jute and shellac.
lines
Loose belts. Adjust or replace, if elongated.
Defective seating of
inlet and delivery Open, clean and refit after careful check.
valve plates.
Wornout piston rings. Replace after checking the related

components.
49
Troubleshooting
Problem : Unloader valve leaky
Check Remedy
Dirty valve seat or torn Unloader bottom lever may be

valve seat. pressing the unloader pin. Adjust the
nut or replace the valve seat.
Problem : During compressor operation air leaks through the cross hole
of unloader
Check Remedy
Dirt between the cone

seat and valve seat of Clean the cone seat and reassemble.
the pressure switch.
Defective valve seat. Replace the valve seat with a new

one.
Problem : Faulty working pressure differential from those of setting in

pressure switch
Check Remedy
This may be due to

Re-adjust.
over adjusting.
Problem : Mal-functioning of pressure switch
Check Remedy
Sparking of contact/
Replace contact assemblies.
melted contact points.
50
Troubleshooting
Problem : Base mounted compressor package vibration
Check Remedy
Check the surface with spirit level

Uneven floor level.
and correct the floor level.
Foundation bolts and

Tighten bolts and nuts
nuts loose.
Problem : Starter chattering
Check Remedy
Loose connection in
starter mains/coil Tighten all the wires in starter.
terminals.
Pressure switch
Check pressure switch function.
malfunctioning.
Check if incoming voltage is more

Low supply voltage.
than 360 V.
51
Troubleshooting
Problem : Contactor tip welding
Check Remedy
Foreign particles Clean contact tips in contactor.

prevent contact Operate the starter in cover closed
closing. condition only. Use proper glands for
incoming connection: plug the unused
cable entry points.
Low supply voltage. Check if incoming voltage is more than

360 V.
Short circuit. Trace and correct fault, and check to

be sure that fuse rating is correct.
Defective starter Replace starter
Problem : Starter tripping
Check Remedy
Set OLR to match the motor current

Wrong OLR set limit. for DOL & 0.58 times the motor
current for star delta starter.
Adjust the pressure switch setting to

Over loading. the rated load.Check NRV function.
Loop lines connected Remove loop lines.

from starter.
52
Troubleshooting
Check Remedy
Check all the three phases are

Single phasing. available at OLR terminals if not check
at starter incoming side & fuse
terminals.
Motor winding short. Check motor winding for correctness.
Provide proper ventilation. Ensure the

High ambient
ambient inside the compressor room
temperature.
is less than 45 Deg. C.
OLR malfunctioning
(Check if the motor Increase the OLR set point slightly
current is equal or less or replace the OLR
than set limit even when
it gives the nuisance
tripping)
Control the fluctuation or stop the

Voltage fluctuation. compressor if the voltage
drops below 360 V
Check the start & stop functions per

hour is less than10 times per hour. If
Frequent start stop. itismore, increase the air receiver
capacity.
53
Troubleshooting
Check Remedy
Set OLR to match the motor current

Wrong OLR set limit. for DOL & 0.58 times the motor
current for star Delta starter.
Adjust the pressure switch setting to

Over loading. the rated load.Check NRV function.
Loop lines connected Remove loop lines.

from starter.
Problem : Star to Delta function (for above 10 hp models)
Check Remedy
Adjust the timer (6-8 sec) so as star

Improper timer setting delta change over takes place with
in 8 sec
Timer / Contactor Check any foreign particles are

( control NO / NC inside the contacts & clean the
points) contacts not same. If it is defective one replace
properly open / close. the contactor / timer.
54
Troubleshooting
Problem : Solenoid valve not working (for above 10 hp models)
Check Remedy
Loose connections of
solenoid valve wires Tighten the earth wire & contactor.
in starter.
Earthing not provided Connect earth wire.

in starter
Contact point in Check if the aux contact is placed in

starter not closed After delta contactor & contact point is
Delta change over. closed after delta change over.
Defective solenoid Replace solenoid valve

valve
Problem : Motor not running in normal condition
Check Remedy
Pressure switch Check pressure switch functions, i.e.

malfunctioning. contact movement.
Check by pressing the contactor in the

Starter coil burnt. starter for 2 seconds. If the coil rotates
is defective, Replace the coil.
55
Troubleshooting
Problem : Motor not running in normal condition
Check Remedy
Single phasing (there is

humming sound & motor Check all phases are available at the
is not producing the motor terminals.
required torque).
Loose connection in
starter terminals / coil
Terminals, Pressure Correct the loose connections.
switch terminals.
Ensure the reasons for OLR trip &reset

OLR trip.
the trip by pressing stop button.
Motor winding burnt. Checks the winding, if faulty replace

the motor.
Problem : Motor winding burnt
Check Remedy
Ensure the ambient inside the

High ambient compressor room is less then 45
temperature. Deg C.
Provide proper ventilation.
Motor fan not rotating. check the motor fan is properly fixed &
rotating with motor.
Short circuit Ensure the correct rating of fuses are

installed & the fuses are not blown.
56
Troubleshooting
Problem : Motor winding burnt
Check Remedy
Check all phase are available at the

Single phasing. motor terminals.
Check fuses are in good condition.
Check starter contacts are in good
condition.
Check OLR is responding to over load.
Check OLR setting in starter.

Over loading. Check pressure setting is with in
limits.
Limit the no of starts per hour to 10 by

Frequent start & stop.
installing a suitable air receiver.
Defective winding. Replace the motor
57
Genuine spares
Protect your precious investments with genuine ELGI spare parts. Stringent
quality checks, over four decades of experience and state-of-the-art
technology makes each and every ELGI genuine spare part superior. ELGI
spares make your compressor last longer and enhance compressor
productivity.
Filters :
# Heavy duty paper or reinforced felt filtering upto 10 micronsize particle.
Valves :
# Super finished stainless steel for corrosion resistance

# Designed for minimum restriction on air flow
58
Genuine spares
Cylinders :
# High grade cast iron castings with close grain structure

# Deep finned for better cooling
# Special honing for better oil control and improved lubrication
Piston & Piston rings :
Piston :
# Low expansion aluminium alloy for better thermal properties
Piston Rings :
# Low expansion aluminium alloy for better thermal properties
59
Genuine spares
Connecting rod & Crank shaft assy :
# Special forged steel to withstand heavy duty conditions
# Special process carried out to improve wear resistance properties
# Crank shafts on both sides supported by heavy duty bearings for better
load carrying capacity
Tune-up kit :
# User-friendly periodic maintenance kit

# Handy and easy to carry
60
Spare parts list
61
62
TS 03 HN
RAC package model : TS 03 120 HN

Fig. No. Description Q t y. Drg./Part No.

RAC Package TS 03 120 HN
160 L – With Electrical 1 S02 428

160 L – Without Electrical 1 S02 429

RAC Package TS 03 120

HN 220 L – Without Electrical 1 S02 431
1 Air receiver, 160 L 1 02 02 2808 0
Air receiver, 220 L 1 02 02 2816 0
2 RAC Unit (02 03 5929 0) 1 X02 0756
3 Bolt Hex. M12x40 4 00 09 06 185
4 Spring washer M12 4 00 09 96 112
5 Nut Hex. M12 4 00 09 48 012
6 Non-Return Valve Assy. 1” BSP 1 A02 0490
7 Elbow assy ¾” BSP 1 02 04 9615 0
8 Bonded seal ¾” BSP 1 00 09 5943 8
9 Safety valve assy.

¼” BSP (02 04 9110 0) 1 A02 0241
10 After cooler Pipe 160 ltr 1 02 03 6568 0
After cooler Pipe 220 ltr 1 02 03 6569 0
11 Connecting piece PSW 1 02 04 9698 0
12 Pressure Switch assy. ½” BSP 1 A02 0018

¼” BSP (Air receiver) 1 A02 0196
14 Ermeto ¼” x 1/8” BSP 1 00 04 2659 A
15 Pressure pipe line assy. NRV to PSW 1 02 04 9642 0
16 Pressure Gauge 3/8” BSP 1 B21 23 43
17 Starter plate 1 02 04 8606 A
63
64
TS 03 HN


18 Starter DOL 1 51 89 0063 0
19 Hose assy. PVC & Wire
Starter to Motor (02 04 8730 0) 1 A02 0217

Starter to Pr.Switch (02 04 8729 0) 1 A02 0216
21 Electric Motor, 3 hp,

3 phase, 50Hz, 415V, 1 A10 0041
22 Motor pulley 1 00 04 1069 0
23 ‘V’ Belt - A70 2 00 09 05 170
24 Tension Adjuster M16x78 2 00 05 1030 B
25 Bolt Hex. M10x40 4 00 09 06 147
26 Spring washer M10 4 00 09 96 110
27 Nut Hex. M10 4 00 09 48 010
28 Belt Guard 160 L 1 02 02 2551 0
Belt Guard 220 L 1 02 02 2629 0
29 Bolt Hex. M8x20 3 00 09 06 115
30 Spring washer M8 3 00 09 96 108
31 Plug 1 ½” NPT 1 02 04 8820 0
32 Reducer 1 ½” NPT x ½” BSP 1 02 04 8818 0
33 Ball Valve assy. ½” BSP 1 B31 27 17
34 Elbow 3/8”F x 3/8” M 1 00 09 74 002
35 Pipe, drain 3/8” BSP 1 02 04 9271 0
36 Ball Valve assy. 3/8” BSP 1 B31 27 25
65
66
RAC unit model : TS 03 120 HN

1 RAC Unit (02 03 5929 0) 1 X02 0756
Cooling fan & Pulley
assembly (02 04 9018 0) 1 A02 0422
2 Compressor pulley 1 ----
3 Cooling fan 1 ----
4 Spring washer M8 9 ----
5 Bolt hex. M8x20 9 ----
6 End disc 1 ----
8 Bolt hex. M10x30 1 ----
9 Air filter assembly 1 A02 0023
67
68

1 Crank case 1 00 02 1279 0
2 Stud M12 x 45 8 00 05 1456 A
3 Gasket, Free end cover 1 00 04 2550 0
4 Free end cover 1 02 03 6545 0
5 Spring washer M8 10 00 09 96 108
6 Bolt Hex. M8x25 10 00 09 06 116
7 Pipe, breather 1 02 04 9285 0
8 Reducer ½” x 1” BSP 1 02 04 9246 0
9 Breather assembly (00 04 1138 0) 1 A02 0030
10 Rink packing, 17x22x2 1 00 05 2186 0
11 Oil Drain plug, 3/8” BSP 1 A02 0033
12 ‘O’ Ring, OLI 1 00 05 2655 0
13 Oil Level Indicator, 1 1/4” BSP 1 00 05 1344 0
14 Conn. rod & Combined Crank shaft
assy. with bearing 1 02 03 6039 0
14a Conn. rod & Combined Crank shaft
assy. without bearing (02 03 5308 0) 1 A02 0231
15 Bearing 6305 1 00 09 03 346
16 Bearing 6307 1 00 09 03 352
17 Gasket, Fly end cover 1 00 04 2551 0
18 Oil seal, B32x45x7 1 00 04 2034 0
19 Fly end cover 1 02 03 5039 0
20 Piston, dia 70 1 00 02 1213 0
21 Circlip, B 18 2 00 09 17 218
22 Gudgeon pin, Dia 18 1 00 05 1430 0
23 Ring, slotted oil control, Dia 70 2 00 04 1684 0
24 Ring, stepped compression, Dia 70 1 00 04 1588 0
25 Ring, Taper plain compression, Dia 70 1 00 04 1587 0
26 Gasket, C/Case to Cylinder, 1 mm 1 00 04 1002 D
27 Cylinder, dia 70 1 00 02 1002 0
28 Spring washer M12 8 00 09 96 112
29 Nut, Hex. M12 8 00 09 48 012
69
70

30 Stud, M12 x 60 3 00 05 2013 A
Stud, M12 x 70 1 00 05 1883 0
31 Valve finger 2 00 03 3096 0
32 Gasket, Cyl. To Valve flat 1 00 04 1154 A
33 Valve Flat 1 00 03 1004 0
34 Gasket, Valve flat to Head 1 00 04 1155 A
35 Centring Bush 4 00 04 2660 0
36 Head, dia 70 Cyl. 1 00 02 1003 B
37 Spring washer M12 8 00 09 96 112
38 Nut, Hex. M12 8 00 09 48 012
39 Piston dia 50 1 00 02 1357 0
40 Circlip B 12 2 00 09 17 212
41 Gudgeon pin, Dia 12 1 00 05 1431 0
42 Ring, slotted oil control, Dia 50 2 00 04 1683 A
43 Ring, stepped compression, Dia 50 1 00 04 1590 A
44 Ring, Taper plain compression, Dia 50 1 00 04 1589 A
45 Gasket, C/Case to Cylinder, 0.25 1 00 04 1150 A
46 Cylinder, dia 50 1 00 02 1004 0
47 Stud, M12 x 60 3 00 05 2013 A
Stud, M12 x 70 1 00 05 1883 0
48 Valve finger 2 00 03 3094 0
50 Valve Flat 1 00 03 1005 0
52 Head, dia 50 Cyl. 1 00 02 1993 0
53 Connector assy ¾’ x 1” BSP 2 02 04 9663 0
54 Ring, Packing 2 00 05 2192 0
55 Inter cooler 1 00 03 1006 A
56 Safety valve assembly,
¼”BSP (00 04 1318 0) 1 A02 0001
57 Name plate, RAC Unit 1 02 03 5180 U
58 Rivet 2 00 04 6454 A
71
72
TS 03 HN
RAC unit model : TS 03 120 HN (Oil bath filter)

RAC Package model : TS 03 120 HN (Oil bath filter)

160 L – With Electrical 1 Z02 291
1 Air receiver, 160 L 1 02 02 2808 0
2 RAC Unit (02 03 5554 0) 1 X02 8546
3 Bolt Hex. M12x40 4 00 09 06 185
4 Spring washer M12 4 00 09 96 112
5 Nut Hex. M12 4 00 09 48 012
7 Elbow assy ¾” BSP 1 02 04 9615 0
8 Bonded seal ¾” BSP 1 00 09 5943 8

¼” BSP (02 04 9110 0) 1 A02 0241
10 After cooler Pipe 1 02 03 6568 0

14 Ermeto ¼” x 1/8” BSP 1 00 04 2659 A
18 Air filter assy oil bath (02 04 9056 0) 1 A02 0430



3 phase, 50Hz, 415V, 1 A10 0041
73
74
TS 03 HN
RAC unit model : TS 03 120 HN (Oil bath filter)

RAC Package model : TS 03 120 HN (Oil bath filter)

22 Motor pulley 1 00 04 1069 0
23 ‘V’ Belt - A70 2 00 09 05 170
25 Bolt Hex. M10x40 4 00 09 06 147
26 Spring washer M10 4 00 09 96 110
27 Nut Hex. M10 4 00 09 48 010
28 Belt Guard 160 L 1 02 02 2551 0
29 Bolt Hex. M8x20 3 00 09 06 115
30 Spring washer M8 3 00 09 96 108
31 Plug 1 ½” NPT 1 02 04 8820 0
32 Reducer 1 ½” NPT x ½” BSP 1 02 04 8818 0
33 Ball Valve assy. ½” BSP 1 B31 27 17
34 Elbow 3/8”F x 3/8” M 1 00 09 74 002
35 Pipe, drain 3/8” BSP 1 02 04 9271 0
75
76
RAC Package model : TS 05 120 HN


1 Air receiver, 220 L 1 02 02 2816 0
2 RAC Unit (02 03 5608 0) 1 X02 0694
3 Bolt Hex. M12x40 4 00 09 06 185
4 Spring washer M12 4 00 09 96 112
5 Nut Hex. M12 4 00 09 48 012
7 Elbow assy ¾” 1 02 04 9615 0
8 Bonded seal ¾“ 1 00 09 5943 8

¼” BSP (02 04 9110 0) 1 A02 0241

14 Ermeto ¼” BSP x 1/8” BSP 1 00 04 2659 A
18 Starter DOL 1 51 89 0103 0

77
78


3 phase, 50Hz, 415V, 1 A10 0061
22 Motor pulley 1 02 04 8509 0
23 ‘V’ Belt – B 74 2 00 09 05 275
Tension Adjuster M16x115 1 00 05 1030 C
25 Bolt Hex. M10x40 4 00 09 06 147
26 Spring washer M10 4 00 09 96 110
27 Belt Guard 1 02 02 2629 0
28 Bolt Hex. M8x20 3 00 09 06 115
29 Spring washer M8 3 00 09 96 108
30 Plug 1 ½” NPT 1 02 04 8820 0
31 Reducer 1 ½” NPT x ¾” BSP 1 02 04 8823 0
32 Ball Valve assy. ¾” BSP 1 B31 27 16
33 Elbow 3/8”F x 3/8” M 1 00 09 74 002
34 Pipe, drain 3/8” 1 02 04 9271 0
79
80

1 RAC Unit (02 03 5929 0) 1 X02 0694
Cooling fan & Pulley

assembly (02 04 9017 0) 1 A02 0423
5 Bolt hex. M8x20 9 ----
6 End disc 1 ----
8 Bolt hex. M10x30 1 ----
Air filter assembly

(incl. 9,10,11&12) 00 02 1397 0 1 A02 0024
9 Bush 1 00 04 3218 0
10 Cover, bottom 1 00 04 3231 0
11 Felt, packing 2 00 03 3222 0
12 Element, filter 1 00 03 1782 0
13 Pre-filter 1 00 03 1783 0
14 Rubber, beading 1 00 04 3233 0
15 Clamp No.1 1 00 04 3232 0
16 Cover, top 1 00 04 3230 0
17 Bolt, hex, M6 x 30 1 00 09 0608 8
18 Nut, hex, M6 2 00 09 4800 7
19 Clamp No.2 1 00 04 2113 0
20 Bolt, hex, M6 x 20 1 00 09 0608 6
81
82

1 Crank case 1 02 02 2560 0
2 Stud M12 x 45 8 00 05 1456 A
4 Free end cover 1 02 03 6545 0
5 Spring washer M8 10 00 09 96 108
6 Bolt Hex. M8x25 10 00 09 06 116
7 Pipe, breather 1 02 04 9285 0
8 Reducer ½” BSP x 1” BSP 1 02 04 9246 0
10 Rink packing, 17x22x2 1 00 05 2186 0
12 ‘O’ Ring, OLI 1 00 05 2655 0
15 Bearing 6305 1 00 09 03 346
16 Bearing 6307 1 00 09 03 352
18 Oil seal, B32x54x7 1 00 04 2034 0
19 Fly end cover 1 02 03 5039 0
20 Piston, dia 90 1 00 32 0318 0
21 Circlip, B 18 2 00 09 17 218
22 Gudgeon pin, Dia 18 1 00 34 0757 0

26 Gasket, C/Case to Cylinder, 0.75 1 00 04 1002 D
27 Cylinder, dia 90 1 02 03 5012 0
28 Spring washer M12 8 00 09 96 112
29 Nut, Hex. M12 8 00 09 48 012
83
84

30 Stud, M12 x 86 3 00 04 7004 A
Stud, M12 x 96 1 00 05 1450 0
31 Valve finger 4 00 03 3097 0
33 Valve Flat 1 00 33 0479 0
35 Centring Bush 4 00 04 2660 0
36 Head, dia 90 Cyl. 1 02 03 6001 0
37 Spring washer M12 8 00 09 96 112
38 Nut, Hex. M12 8 00 09 48 012
39 Nipple, Pipe 1 ¼” BSP 1 00 04 3217A
40 Piston dia 50 1 00 02 1357 0
41 Circlip B 12 2 00 09 17 212
42 Gudgeon pin, Dia 12 1 00 05 1431 0
43 Ring, slotted oil control, Dia 50 2 00 04 1683 A
44 Ring, stepped compression, Dia 50 1 00 04 1590 A
45 Ring, Taper plain compression, Dia 50 1 00 04 1589 A
46 Gasket, C/Case to Cylinder, 0.25 1 00 04 1004 D
47 Cylinder, dia 50 1 00 02 1004 0
48 Stud, M12 x 60 3 00 05 2013 A
Stud, M12 x 70 1 00 05 1883 0
49 Valve finger 2 00 03 3094 0
51 Valve Flat 1 00 03 1005 0
53 Head, dia 50 Cyl. 1 00 02 1993 0
54 Connector assy 2 02 04 9620 0
55 Ring, Packing 2 00 05 2191 0
56 Inter cooler 1 00 33 0525 0
¼”BSP (00 04 1318 0) 1 A02 0001
58 Name plate, RAC Unit 1 02 03 5180 V
85
86
RAC package model : TS 07 120 HN - 220 ltrs


1 Air receiver, 220 L 1 02 02 2816 0
2 RAC Unit (02 03 5994 0) 1 X02 0758
3 Bolt Hex. M12x40 4 00 09 06 185
4 Spring washer M12 4 00 09 96 112
5 Nut Hex. M12 4 00 09 48 012
7 Elbow assy 1 02 04 9611 0
8 Bonded seal 1 00 09 5943 8

¼” BSP (02 04 9110 0) 1 A02 0241

14 Ermeto ¼” BSP x 1/8” BSP 1 00 04 2659 A
18 Starter DOL 1 51 89 0153 0


87
88

21 Electric Motor, 7.5 hp,
3 phase, 50Hz, 415V, 1 A10 0071
22 Motor pulley 1 02 04 8520 0
23 ‘V’ Belt – B 74 2 00 09 05 275
25 Bolt Hex. M10x40 4 00 09 06 147
26 Spring washer M10 4 00 09 96 110
27 Nut, hex M10 4 00 09 48 010
28 Belt Guard 1 02 02 2629 0
29 Bolt Hex. M8x20 3 00 09 06 115
30 Spring washer M8 3 00 09 96 108
31 Plug 1 ½” NPT 1 02 04 8820 0
32 Reducer 1 ½” NPT x ¾” BSP 1 02 04 8823 0
34 Elbow 3/8”F x 3/8” M 1 00 09 74 002
35 Pipe, drain 3/8” 1 02 04 9271 0
89
90

500 L – 7.5 HP 50 Hz 1 Z02 175
1 Air receiver, 500 L 1 02 02 2695 0
2 RAC Unit (02 03 5994 0) 1 X02 0758
3 Bolt Hex. M12x40 4 00 09 06 185
4 Spring washer M12 4 00 09 96 112
5 Nut Hex. M12 4 00 09 48 012
7 Elbow assy. 1” 1 02 04 9611 0
8 Bonded Seal 1” 1 00 09 5943 9

¼” BSP (02 04 9110 0) 1 A02 0241

14 Ermeto ¼” BSP x 1/8” BSP 1 00 04 2659 A
16 Pressure Gauge ¼” BSP 1 B21 23 35
17 Starter DOL 1 51 89 0153 0
18 Hose assy. starter to motor 1 A02 0211
19 Hose assy. Starter to psw 1 A02 0213
20 Electric Motor, 7.5 hp,

3 phase, 50Hz, 415V, 1 A10 0071
21 Motor pulley 1 02 04 8520 0
22 ‘V’ Belt – B 76 2 00 09 05 275
91
92

24 Bolt Hex. M10x40 4 00 09 06 147
25 Spring washer M10 4 00 09 96 110
26 Nut, hex M10 4 00 09 48 010
27 Belt Guard 1 02 02 2629 0
28 Bolt Hex. M8x20 3 00 09 06 115
29 Spring washer M8 3 00 09 96 108
30 Plug 2 ” NPT 1 02 04 8821 0
31 Reducer 2” NPT x ¾” BSP 1 02 04 8819 0
33 Elbow 3/8”F x ½” M 1 00 09 74 003
34 Pipe, drain 3/8” 1 02 04 9271 0
93
94

1 RAC Unit (02 03 5994 0) 1 X02 0758
Cooling fan &

Pulley assembly (00 04 7765 0) 1 A02 0056
5 Bolt hex. M8x20 9 ----
6 End disc 1 ----
8 Bolt hex. M12x35 1 ----
Air filter assembly (00 02 1397 0) 1 A02 0024
9 Bush 1 00 04 3218 0
10 Cover, bottom 1 00 04 3231 0
11 Felt, packing 2 00 03 3222 0
12 Element, filter 1 00 03 1782 0
13 Pre-filter 1 00 03 1783 0
14 Rubber, beading 1 00 04 3233 0
15 Clamp No.1 1 00 04 3232 0
16 Cover, top 1 00 04 3230 0
17 Bolt, hex, M6 x 30 1 00 09 0608 8
18 Nut, hex, M6 2 00 09 4800 7
19 Clamp No.2 1 00 04 2113 0
20 Bolt, hex, M6 x 20 1 00 09 0608 6
95
96
RAC unit model : TS 07 120 HN - 200/500 ltrs

RAC unit (02 03 5994 0) 1 X 02 0758
1 Crank case 1 00 02 1278 0
2 Stud M12 x 45 8 00 05 1456 A
4 Free end cover 1 02 03 6546 0
5 Spring washer M8 12 00 09 96 108
6 Bolt Hex. M8x25 12 00 09 06 116
7 Pipe, breather 1 02 04 9285 0
8 Reducer ½” BSP x 1” BSP 1 02 04 9246 0
10 Rink packing, 17x22x2 1 00 05 2186 0
12 ‘O’ Ring, OLI 1 00 05 2655 0
15 Bearing 6307 1 00 09 03 352
16 Bearing 6309 1 00 09 03 358
18 Oil seal, B45x60x12.5 1 00 04 2035 0
19 Fly end cover 1 02 03 5463 0
20 Piston, dia 100 1 02 03 6183 0
21 Circlip, B 20 2 00 09 17 220
22 Gudgeon pin, Dia 20 1 00 05 1419 0
24 Ring, stepped compression, Dia100 2 00 04 1757 0
Gasket, C/Case to Cylinder, 1 mm 2 00 04 1004 D
27 Cylinder, dia 100 1 00 02 1010 D
28 Spring washer M12 8 00 09 96 112
97
98

29 Nut, Hex. M12 8 00 09 48 012
30 Stud, M12 x 86 3 00 04 7004 A
Stud, M12 x 96 1 00 05 1450 0
31 Valve finger 4 00 03 3097 0
33 Valve Flat 1 00 03 1007 0
35 Centring Bush 4 00 04 2660 0
36 Head, dia 100 Cyl. 1 00 02 1238 C
37 Spring washer M12 8 00 09 96 112
38 Nut, Hex. M12 8 00 09 48 012
39 Nipple, Pipe 1 ¼” BSP 1 00 04 3217A
40 Piston dia 60 1 00 02 1210 0
41 Circlip B 18 2 00 09 17 218
42 Gudgeon pin, Dia 18 1 00 05 1418 0
46 Cylinder, dia 60 1 00 02 1011 0
47 Stud, M12 x 60 3 00 05 2013 A
Stud, M12 x 70 1 00 05 1883 0
48 Valve finger 2 00 03 3095 0
49 Gasket, Cyl. To Valve flat 1 00 04 1152 B
50 Valve Flat 1 00 03 1008 0
51 Gasket, Valve flat to Head 1 00 04 1153 B
52 Head, dia 60 Cyl. 1 00 02 1012 0
53 Connecting piece 2 02 04 9609 0
54 Ring, Packing 2 00 05 2191 0
55 Inter cooler 1 00 03 1009 A
¼”BSP (00 04 1318 0) 1 A02 0001
57 Name plate, RAC Unit 1 02 03 5180 R
99
100


1 Air receiver, 220 L 1 02 02 2820 0
2 RAC Unit (02 03 5610 0) 1 X02 0696
3 Bolt Hex. M12x50 4 00 09 06 187
4 Spring washer M12 4 00 09 96 112
5 Nut Hex. M12 4 00 09 48 012
6 Non-Return Valve Assy. 1" BSP 1 A02 0490
7 Connector assy ¾” x M36 1 02 04 9751 0
8 Bonded seal washer 1" 1 00 09 5943 9
9 Safety valve assy. ¾” BSP,

After Cooler (02 04 9114 0) 1 A 02 0245
10 Elbow assy 1 02 04 9681 0
11 After cooler Pipe Assy. No.2 1 02 03 6654 0
15 Safety valve assy. ½” BSP,

Air receiver (02 04 9113 0) 1 A02 0244
16 Pressure Gauge 3/8" BSP 1 B21 23 43
17 Ring Packing10.5X16.5X2 1 00 05 2194 0
18 Ermeto ¼” BSP x 1/8" BSP 1 00 04 2659 A
19 Pressure pipe line assy. 1 02 04 9711 0
20 DOL Starter 1 51 89 0203 0
101
102



3 phase, 50Hz, 415V, 1 A10 0081
Electric Motor, 10 hp,

3 phase, 50Hz, 415V, KEW 1 10*485449
24 Motor pulley 1 00 04 3228 0
25 ‘V’ Belt – B 76 2 00 09 05 277
27 Tension Adjuster M16x115 1 00 05 1030 C
28 Bolt Hex. M10x40 4 00 09 06 147
29 Spring washer M10 4 00 09 96 110
30 Nut, Hex. 4 00 09 48 010
31 Belt Guard 1 02 02 2828 0
31a Clamp 1 02 04 9449 0
32 Bolt Hex. M8x20 1 00 09 06 115
33 Spring washer M8 1 00 09 96 108
34 Plug 1 1/2" NPT 1 02 04 8820 0
35 Reducer 1 ½” NPT x ¾” BSP 1 02 04 8823 0
37 Elbow 3/8"F x 3/8" M 1 00 09 74 002
38 Pipe, drain 3/8" BSP 1 02 04 9271 0
39 Ball Valve assy. 3/8" BSP 1 B31 27 25
103
104
RAC package model : TS 10 120 HN - 420 & 500 ltrs

420 L – With El ectrical 1 S02 463



1 Air receiver, 420 L 1 02 02 3003 0
Air receiver, 500 L 1 02 02 2827 0
2 RAC Unit (02 03 5610 0) 1 X02 0696
3 Bolt Hex. M12x50 4 00 09 06 187
4 Spring washer M12 4 00 09 96 112
5 Nut Hex. M12 4 00 09 48 012
7 Connector assy 1 02 04 9751 0
8 Bonded washer 1 00 09 5938 7

After Cooler (02 04 9114 0) 1 A 02 0245
10 Elbow assy 1 02 04 9681 0

Air receiver (02 04 9113 0) 1 A02 0244
17 Ring Packing10.5X16.5X2 1 00 05 2194 0
105
106

18 Ermeto ¼” BSP x 1/8" BSP 1 00 04 2659 A
19 Pressure pipe line assy. 1 02 04 9711 0
20 DOL Starter 1 51 89 0203 0



3 phase, 50Hz, 415V, 1 A10 0081

3 phase, 50Hz, 415V, KEW 1 10*485449
24 Motor pulley 1 00 04 3228 0
25 ‘V’ Belt – B 76 2 00 09 05 277
27 Tension Adjuster M16x115 1 00 05 1030 C
28 Bolt Hex. M10x40 4 00 09 06 147
29 Spring washer M10 4 00 09 96 110
30 Nut, Hex. 4 00 09 48 010
31 Belt Guard 1 02 02 2828 0
32 Bolt Hex. M8x20 3 00 09 06 115
33 Spring washer M8 3 00 09 96 108
34 Plug 2" NPT 1 02 04 8821 0
35 Reducer 2" NPT x ¾” BSP 1 02 04 8819 0
37 Elbow 3/8"F x 1/2" M 1 00 09 74 003
38 Pipe, drain 3/8" BSP 1 02 04 9271 0
107
108

RAC Unit 1 X 02 0696
01. Crankcase 1 00 02 1394 0
02. Stud, M12 x 45 12 00 05 1456 A
03. Gasket, free end 1 00 04 3199 0
04. Cover, free end 1 00 03 1809 0
05. Washer, spring, rectangular, M8 8 00 09 96 108
06. Bolt, hex M8 x 25 8 00 09 06 116
07. Pipe, breather, 1/2'' BSP 1 00 04 1361 B
08. Reducer 1" x 1/2" BSP 1 02 04 9246 0
09. Valve assembly, breather 1 A 020030
10. Ring, packing, 17 x 22 x 2 1 00 05 2186 0
11. Drain plug assembly 1 A020033
12. 'O' ringOLI 1 00 05 2655 0
13. Indicator, oil level, 11/4'' BSP 1 00 05 1344 0
14. Connecting rod and crankshaft

assembly (02 02 2753 0) 1 A020427
15. Bush, Dia 20 Gudgeon pin 2 00 05 2311 0
16. Needle roller bearing TA 1825 ZOH 1 00 09 03 712
17. Bearing, ball single row, SKF 6310 2 00 09 03 361
18. Key, 10 x 8 x 60 1 00 05 1037 0
19. Gasket, fly end 1 00 04 3198 0
20. Seal, oil, B45 x 60 x 12.5 1 00 04 2035 0
21. Cover, fly end 1 00 03 1777 0
23. Bolt, hex, M8 x 25 8 00 09 96 116
24. Piston dia 100 2 02 03 6183 0
25. Pin, gudgeon, dia 20 2 00 05 1419 0
109
110

26. Circlip, B20 4 00 09 1722 0
27. Ring, slotted, oil control dia 100 4 00 04 1686 0
28. Ring, stepped compression, dia 100 4 00 04 1757 0
29. Ring, taper plain compression, dia 100 2 00 04 1685 0
30. Gasket Crankcase to dia 100 cyl 0.8 2 00 04 1004 C
31. Cylinder, dia 100 2 00 02 1010 D
33. Nut, hex M12 8 00 09 99 808
34. a) Stud, M12 x 86 6 00 04 7004 A
b) Stud, M12 x 96 2 00 05 1450 0
35. Gasket cyl to valve flat 2 00 04 1156 A
36. Valve finger 8 00 03 3097 0
37. Flat valve dia 2 00 03 1007 0
38. Bush Centering 2 00 04 2660 0
39. Packing cyl head to valve flat 2 00 04 6210 A
40. Head, dia 100 cylinder 2 00 02 1238 C
42. Nut, hex, M12 9 00 09 99 808
43. Nipple, 11/4'' BSP 2 02 04 9718 0
44. Dowety washer 3 00 09 5943 9
45. Connector, Housing 1'' BSP 3 02 04 9678 0
46. Ring, packing, 30 x 38 x 2 2 00 05 2194 0
47. Elbow assy 3 02 04 9678 0
48. Piston, dia 70 1 00 02 1213 0
49. Pin, gudgeon, dia 18 1 00 05 1430 0
111
112

50. Circlip, internal,B18 2 00 09 17 218
51. Ring, slotted, oil control dia 70 2 00 04 1684 0
52. Ring stepped, compression dia 70 1 00 04 1588 0
53. Ring, plain compression, dia 70 1 00 04 1587 0
54. Gasket Crankcase, dia 70 Cyl. 0.75 1 00 04 1002 A
55. Cylinder, dia 70 1 00 02 10020
57. Nut, hex, M12 4 00 09 99 808
58. Stud, M12 x 60 4 00 05 2013 A
59. Valve, finger type, dia 70 cylinder 2 00 03 3096 0
60. Gasket cyl to valve flat 1 00 04 1154 A
61. Flat, valve, dia 70 cylinder 1 00 03 1004 0
62. Bush,centering 2 00 04 2660 0
63. Gasket cyl head to valve flat 1 00 04 1155 A
64. Head, cylinder dia 70 1 00 02 1393 0
65. Washer, spring rectangular, M12 4 00 09 96 112
66. Nut,hex, M12 4 00 09 99 808
67. Dowety washer 1 00 09 5943 7
68. Connector, 7/8'' BSP 1 02 04 9679 0
*69. Ring, packing, 30 x 38 x 2 1 00 05 2194 0
*70. Ermeto assy 1 02 04 9610 0
71. Rivet 4 00 04 6454 A
72. Name Plate 1 02 03 5180 X
* Not showm in the figure
113
114
Reciprocating air compressor package - tank mounted model : TS 10 120 HT - 420 Ltrs
RAC package model : TS 10 120 HT

RAC Package TS 10 120 HT - 420 Ltrs 1 S 02462
01 AIR RECEIVER 1 02 02 3003 0/A
02 BELT GUARD 1 02 03 6122 0
03 RAC UNIT TS 10 120 HT 1 X02 0831
04 AFTERCOOLER PIPE NO 1 1 02 03 6142 0
05 AFTERCOOLER PIPE NO 2 1 02 03 6772 0
06 ELBOW AFTERCOOLER 1 02 04 9428 0
115
116
Reciprocating air compressor package - tank mounted model : TS 10 120 HT
RAC unit model : TS 10 120 HT

RAC Unit 1 X02 0831
01 CRANKCASE MACHINING 1 02 03 6103 0

02 GASKET FREE END 1 02 04 9444 0
03 COVER FREE END M/C 1 02 03 6154 0
04 WASHER SPRING REC SEC M8 10 00 09 9610 8
05 BOLT HEX M8X20 8.8 ZYP 5-8M 10 00 09 0611 5
06 BRG 6310 Z 1 00 09 0336 2
07 CON ROD & C/SHAFT ASSY 1 A02 0461
08 BRG 6310 1 00 09 0336 1
09 SEAL OIL B45X60X12.5 SS07/10 1 00 04 2035 0
10 GASKET FLY END 1 02 04 9409 0
11 COVER FLY END M/C 1 02 03 6106 0
12 STUD M12 X 45 C/CASE TO 50 CYL 8 00 05 1456 A
13 GASKET 0.75C/CASE TO CYL 1 02 04 9410 0
14 PISTON ASSY DIA 127
1 02 04 9436 0
15 CIRCLIP INTERNAL 20 MM
16 CYL DIA127 M/C 1 02 03 6094 0
17 STUD M12 X 60 C/CASE TO 70 CYL SS 6 00 05 2013 A
18 GASKET 0.75 127DIA CYL TO V/F 1 02 04 9412 0
19 REED VALVE ASSY 127 1 02 04 9390 0
20 GASKET VALVE FLAT TO 127 CYLIN 1 02 04 9413 0
21 HEAD CYLINDER LP DIA 127 MACHI 1 02 03 6100 0
22 WASHER SPRING REC SEC M12 16 00 09 9611 2
23 NUT HEX M12 8 ZYP 16 00 09 4801 2
24 GASKET 0.75 C/CASE TO CYL 70 DIA 1 02 04 9411 0
25 PISTON ASSY DIA 70
1 02 04 9438 0
26 CIRCLIP INTERNAL 18 MM
117
118
Reciprocating air compressor package - tank mounted model : TS 10 120 HT
RAC unit model : TS 10 120 HT

27 CYL DIA 70 M/C 1 02 03 6096 0
28 STUD M12X70 SS02/03/05 TS02/03 2 00 05 1883 0
29 GASKET 0.75 70 DIA CYL TO V/F 1 02 04 9412 0

30 VALVE FINGER 1 00 03 3096 0
31 GASKET VALVE FLAT TO CYLINDER 1 00 04 1154 A
32 CYL HEAD DIA 70 M/C TS10 1 02 03 6098 0
33 RING PKG 17X22X2 3/8 PLUG” 2 00 05 2186 0
34 PLUG ASSY DRAIN 3/8BSP” 1 A02 0033
35 IND OIL LEVEL 1 1/4” BSP 1 00 05 1344 0
36 O RING OLI NRV 1 1/2", 1 00 05 2655 0
37 PLUG 3/4” BSP 1 00 04 2652 0
38 VALVE ASSY BREATHER 1 A02 0436
39 QUICK FITTINGS CONNECTOR 1/4” BSP1 00 09 2051 2
40 QUICK FITTING 1 00 09 2061 2
41 PLASTIC TUBING 1 00 09 1925 2
42 ELBOW ASSY 2 02 04 9678 0
43 NIPPLE PIPE 1 1/4” BSP 1 00 04 3217 A
44 BUSH RUBBER 1/L AIR FILTER B 1 00 04 3218 0
45 FILTER ASSY 1/L AIR B TYPE 1 A02 0464
46 INTERCOOLER ASSY 1 02 03 6773 0
47 FLY WHEEL M/C 1 02 03 5865 0
48 DISC END SS15 EXPORT 1 00 05 1036 A
49 BOLT HEX M12X30 1 00 09 0618 3
50 PLATE NAME RAC UNIT 1 02 03 6514 0
51 RIVET DIA2.5X4.5 NAME PL 4 00 04 6454 A
119
120

RAC Package TS 15 120 HN 500 L
– With Electrical 1 S02 469
RAC Package TS 15 120 HN 500 L

– Without Electrical 1 S02 470
1 Air receiver, 500 L 1 02 02 2827 0
2 RAC Unit (02 03 6177 0) 1 X02 0837
3 Bolt Hex. M12x50 4 00 09 06 187
4 Spring washer M12 4 00 09 96 112
5 Nut Hex. M12 4 00 09 48 012
7 Connector assy ¾” x M36 1 02 04 9680 0

After Cooler (02 04 9114 0) 1 A 02 0245
9 DUV Cum Solenoid Valve 1 02 24 3225 0
10 Silencer ½” BSP 1 00 04 7001 A
13 Connecting piece with nut, PSW 1 02 04 9699 0
14 Pressure Switch assy. ½” BSP 1 B00 18005 10002

Air receiver (02 04 9113 0) 1 A02 0244
17 Dowety washer 1 00 09 5938 7
18 Plug 1/8" BSP 1 00 05 1887 A
19 Starter, Star Delta 1 51 89 0303 1
121
122


Starter to Pr.Switch 1 02 04 9538 0

3 phase, 50Hz, 415V, 1 10*403041

3 phase, 50Hz, 415V, KEW 1 10*485649
23 Motor pulley 1 00 04 3570 B
24 ‘V’ Belt – C 80 2 00 09 05 433
26 Bolt Hex. M12x50 4 00 09 06 187
27 Spring washer M12 4 00 09 96 112
28 Nut, Hex. M12 4 00 09 48 012
29 Belt Guard 1 02 02 2828 0
30 Bolt Hex. M8x20 3 00 09 06 115
31 Spring washer M8 3 00 09 96 108
32 Plug 2" NPT 1 02 04 8821 0
33 Reducer 2" NPT x ¾” BSP 1 02 04 8819 0
35 Elbow 3/8"F x 1/2" M 1 00 09 74 003
36 Pipe, drain 3/8" BSP 1 02 04 9271 0
123
124

0 1. RAC Unit 1 X 02 0837
02. Pulley, Compressor
03. Fan, cooling
04. Washer, spring rectangular, M8 1 A 02 0058
05. Bolt, hex, M8 x 20
06. Disc, end 1 00 05 1036 A
08. Bolt, hex, M12 x 35 1 00 09 99 804
09. Pipe dampening 1 02 04 9692 0
10. Valve assembly, drain, 1/4'' BSP 1 A02 0045
11. Valve assembly, safety. 3/8'' BSP 1 A02 0002
12. Pipe assembly, connecting No.3 1 02 04 9691 0
13. Pipe assembly, connecting No.2 2 02 04 9689 0
14. Ermeto assy 3/4'' 3 02 04 9679 0
15. Bush 2 00 04 3218 0
16. Filter assy 2 A02 0024
125
126

01. Crankcase 1 00 02 1394 0
02. Stud, M12 x 45 12 00 04 1456 A
03. Gasket, free end 1 00 04 3199 0
04. Cover, free end 1 00 03 1809 0
06. Bolt Hex M8 x 25 6 00 09 0611 6
07. Pipe, 1/2'' BSp 1 00 04 1361 0
08. Reducer 1/2'' x 1'' BSP 1 00 04 3655 0
09. Breather Assembly 1 A 02 0030
10. Drain Plug Assembly 3/8'' 1 A 02 0033
11. Packing Ring 3/8'' drain plug 1 00 05 2186 0
12. O ring 1 00 05 2655 0
13. Oil level indicator 1 1\4'' BSP 1 00 05 1344 0
14. Connecting Rod & Crankshaft
assembly (02 02 2753 0) 1 A 02 0427
15. Bush dia 20 Gudgeoon pin 2 00 05 2311 0
16. BRG Needle roller 1 00 09 0371 2
17. Ball bearing single row SKF 6310 2 00 09 0336 1
18. Key 1 00 05 1037 0
19. Gasket, fly end 1 00 04 3198 0
20. Oil seal, B45 x 60 x 12.5 1 00 04 2035 0
21. Cover, fly end 1 00 03 1777 0
127
128

22. Piston assy dia 100
23. Gudgeon pin dia 20 2 02 04 9456 0
24. Circlip B20
25. Ring slotted oil control
26. Ring stepped Compression 2 02 24 3413 9
27. Ring taper plain compression
28. Gasket Crankcase to

dia 100 cyl.0.8 mm 2 00 04 1004 C
29 Cylinder dia 100 2 00 02 1010 A
30 Spring washer M12 8 00 09 9611 2
31 Hex Nut M12 8 00 09 4801 2
32. Stud M12 x 60 10 00 05 2013 A
Stud M12 x 75 2 00 05 2014 0
33. Gasket, big disc valve, dia 100 cyl. 4 00 05 1921 0
34. Disc valve assembly, dia 100 2 A 02 0042
35. Gasket, small, disc valve dia 100 cyl. 2 00 05 1922 0
36. Cylinder head, dia 100 2 00 02 1239 A
37. Spring washer, M12 12 00 09 9611 2
38. Hex nut M12 12 00 09 4801 2
39. Pipe nipple 2 02 04 9718 0
40. Bonded seal 2 00 09 5943 9
*41. Elbow assy 1'' BSP 2 02 04 9678 0
*42. Bonded seal 7/8" 1 00 09 5943 7
*43. Elbow assy 7/8'' 1 02 04 9679 0

129
130

44. Piston assy dia 70
45. Gudgeon pin, dia 18 1 00 04 7775 0
46. Circlip B18
47. Ring slotted , oil control
48. Ring stepped compression 1 02 24 0104 9
49. Ring taper plain compression
50. Gasket, crankcase to

dia 70 cylinder 0.75 mm 1 00 04 1002 A
51. Cylinder dia 70 1 00 02 1002 0
52. Valve finger dia 70 2 00 03 3096 0
53. Gasket Cyl. to valve flat 1 00 04 1154 A
54. Valve flat, dia 70 cylinder 1 00 03 1004 0
55. Bush Centering 2 00 04 2660 0
56. Gasket Valve flat to head 1 00 04 1155 A
57. Cylinder, head dia 70 1 00 02 1393 0
*58. Connector assy 1 02 04 9620 0
*59. Ring packing 1 00 05 2186 0
*60. Pipe nipple 1 1/4" BSP 2 02 04 9718 0

131
2a 2a
2 2
2b 2b
2c 2c
1 1
1a 1a
1b 1b
1c 1c
2c 2c
Piston assembly dia - 50 Piston assembly dia - 60
2a
2
2b
2c
1a
1b
1c
2c
Piston assembly dia - 70
132
Piston assembly
Piston assembly dia 50

1 Piston with gudgeon pin
1a Piston dia 50 1 1 00 04 7772 0
1b Gudgeon pin dia 12 1
1c Circlip B 12 2 00 09 1721 2
2 OBS Piston Rings, dia 50

2a Ring, taper plain compression, dia 50 1
1 02 24 0102 9
2b Ring, stepped compression, dia 50 1
2c Ring, slotted oil control, dia 50 2

1a Piston dia 60 1 1 00 04 7773 0
1c Circlip B 18 2 00 09 1721 8
1 02 24 0103 9
2b Ring, stepped compression, dia 60 1

1a Piston dia 70 1 1 00 04 7775 0
1c Circlip B 18 2 00 09 1721 8
2b Ring, stepped compression, dia 70 1 1 02 24 0104 9
133
2a
2
2b
2c
1a
1b
1c
2c
Piston assembly dia - 90 Piston assembly dia - 100
134
Piston assembly
Piston assemblydia 90
Fig. No. Description Qty. Drg./Part No.

1a Piston dia 90 1 1 00 34 0820 0
1c Circlip B 18 2 00 09 1721 8
2 OBS Piston ring dia 90
2a Ring, plain compression, dia 90 1
Piston assemblydia 100

1a Piston dia 100 1 1 02 04 9456 0
1c Circlip B 20 2 00 09 17 22 0
2 OBS Piston ring dia 100
2a Ring, plain compression, dia 100 1
135
2
5
4
Piston Assembly Dia 70 - Model 120 HT
Piston Assembly Dia 127 Model TS 10 120 HT
136
Piston assembly
Piston assemblydia 70 Model - TS 10HT

1 Piston with gudgeon pin 1 02 04 9437 0
2 Ring, taper plain compression 1
3 Ring, stepped compression 1
4 Oil ring expander 1 02 24 0250 9
5 Oil ring segment 2
Piston assemblydia 127 Model - TS 10HT

1 Piston with gudgeon pin 1 02 04 9436 0
2 Ring, taper plain compression 1
3 Ring, stepped compression 1
4 Oil ring expander 1 02 24 0249 9
5 Oil ring segment 2
137
Inlet air filter assembly Safety Valve assembly 1/2" BSP - Air receiver
Safety Valve Assembly 3/4" BSP - Air receiver
138
Inlet Air Filter Assembly
Fig. No. Description Qty. Drg. /Part No.
Inlet Air Filter Assembly (02 24 0310 9) 1 A 02 0224

1 Top cover 1 00 04 3230 0
2. Pre-filter 1 00 03 1783 0
3. Filter element 1 00 03 1782 0
4. Bottom cover 1 00 04 3231 0
5. Clamp No.1 1 00 04 3232 0
6. Rubber beading 1 00 04 3233 0
7. Hex. bolt M6 x 30 1 00 09 06 088
8. Hex. nut M6 2 00 09 48 007
9. Clamp No.2 1 00 04 2113 0
10. Hex. Bolt M6 x 20 1 00 09 06 086
11. Felt seat 1 00 04 3222 0
Safety Valve Assembly 1/2'' BSP - Air Receiver

Safety Valve Assembly 3/4'' BSP - Air Receiver
Fig. No. Description Qty. Drg. /Part No.
Safety Valve Assembly 1/2'' BSP ( 02 04 9113 0 ) 1 A02 0244
Safety Valve Assembly 3/4'' BSP ( 02 04 9114 0 ) A02 0245
1 Housing 1\2'' BSP 1 ----
Housing 3/4'' BSP 1 ----
2. Valve cone 1 ----
3. Actuating rod 1 ----
4. Spring 1 ----
5. Lock nut (Pressure adjuster) 1 ----
6. Pressure adjuster 1 ----
7. Distance bush 1 ----
8. Lock nut 1 ----
9. Cover 1 ----
10. Ring 1 ----
11. Valve seat 1 ----
12. Spring seat 1 ----
139
Delivery unloader valve cum Non - return valve
Solenoid valve assembly assembly - 1" BSP
140
DUV cum Solenoid valve assy & NRV assembly

DUV cum Solenoid valve assembly - 02 24 3225 0
-1 Spare parts kit of DUV 1 K 02 06 076
-2 Valve seat 1 -
-3 'O' rings 4 -
-4 Plunger 1 -
Non - return valve assembly - 1” BSP

NRV assembly (02 03 6429 0) 1 A 02 0490
-1 Housing, top 1 ----
-2 Housing, bottom 1 ----
-3 Seat, valve 1 ----
-4 Spring 1 ----
141
Pressure switch assy
with unloader valve
142
Pressure switch assembly with unloader valve.

Pressure switch assy.
with unloader valve (00 02 2322 0) 1 A 02 0018
-1 Cover 1 00 03 1045 0
-2 Packing 1 00 04 1171 0
-3 Main spring 1 00 04 8649 0
-4 Spring seat 1 00 05 1209 0
-5 Flange 1 00 05 1020 0
-6 Spindle seat 1 00 05 1330 0
-7 Diaphragm 1 00 05 1201 0
-8 Hex. bolt M6 x 30 5 02 09 06 088
-9 Bottom flange 1 00 04 1278 0
-10 Hex. bolt M6 x 40 1 02 09 06 090
-11 Hex. nut M6 6 02 09 4800 0
143
Breather valve assy Breather valve assy
(for TS 10 HT model)
Reed valve assy 127

(for TS 10 HT model)
144
Valve assembly
Breather Valve Assembly

Breather valve assy. (00 04 8487 0) 1 A 02 0201
-1 Breather bottom 1 ----

-2 Diaphragm 1 ----
-3 Breather top 1 ----
-4 CSK screw M6 x 10 2 ----
Breather Valve Assembly (for TS 10 HT model)

1 Housing, Breather 1 02 04 9084 0
2 Breather top 1 02 04 9083 0
3 Spring washer 4 00 09 9610 5
4 Hexagon socket head cap screw 4 00 09 8504 7

5 Diaphragm, Breather 4 00 05 1006 0
Reed Valve Assembly 127 (for TS 10 HT model)

Reed valve assembly 127 1 02 04 9390 0
145
Kit spares
Kit, tune up, TS 03 120 HN, tank mounted for 2500 hours
Kit No (02 24 3387 9) for 2500 Hrs ............................................. K 0206099
S.No. Description Qty. Drg. /Part No.
1 Filter element assembly 1 00 04 4371 0
2 Ring, slotted oil control, dia 70 2
3 Ring, stepped compression, dia 70 1 02 24 0104 9
4 Ring, taper plain compression, dia 70 1
6 Ring, taper stepped compression, dia 50 1 02 24 0102 9
8 Valve finger, dia 70 cyl 2 00 03 3096 0

10 Gasket, c/case to cylinder, 0.75 2 00 04 1002 A
11 Gasket, c/case to cylinder, 0.4 2 00 04 1002 B
12 Gasket, c/case to cylinder, 0.25 2 00 04 1002 C
13 'O' ring, oil level indicator 1 00 05 2655 0
14 Ring, packing, 17x22x2 1 00 05 2186 0
15 Ring, packing, 27.5x32x2 1 00 05 2193 0
16 Ring, packing, 24.5x30x2 2 00 05 2192 0
17 Valve, breather 1 00 05 1006 0
18 Gasket, cyl to valve flat, dia 70 cyl. 1 00 04 1154 A
19 Gasket, valve flat to head, dia 50 cyl. 1 00 04 1155 A
20 Gasket, cyl to valve flat, dia 50 cyl. 1 00 04 1150 A
22 1” NRV kit 1 02 24 0313 9
23 "O" Ring, 31.34 x 3.53, DUV 1 00 05 1031 A
24 Diaphragm, dia 86 x 3.5 PSW 1 00 05 1201 0
25 Packing, Rubber, PSW 1 00 04 1171 0
146
Kit spares
Kit No (02 24 3388 9) for 2500 Hrs ............................................. K 02 06 100

2 Felt, packing, air filter 2 00 04 3222 0
7 Ring, taper stepped compression, dia 50 1 02 24 0102 9
9 Valve finger, 4 00 03 3097 0
10 Valve finger, 2 00 03 3094 0
18 Ring, packing, 17x22x2 1 00 05 2186 0
19 Ring, packing, 27.5x32x2 1 00 05 2193 0
20 Ring, packing, 24.5x30x2 2 00 05 2192 0
21 Valve, breather 1 00 05 1006 0
22 Gasket, cyl. to valve flat, dia 90 cyl. 1 06 04 0013 A
26 1” NRV kit 1 02 24 0313 9
27 "O" Ring, 31.34 x 3.53, DUV 1 00 05 1031 A
147
Kit spares
Kit No (02 24 3389 9) for 2500 Hrs ............................................. K 02 06 101

2 Seat 2 00 04 3222 0

9 Valve finger, dia 90/100 cyl. 4 00 03 3097 0
15 Ring, packing, 17x22x2 1 00 05 2186 0
16 Ring, packing, 30x38x2 1 00 05 2191 0
17 Ring, packing, 27x35x2 2 00 05 2184 0
18 Valve, breather 1 00 05 1006 0
21 Gasket, cyl. to valve flat, dia 60 cyl. 1 00 04 1152 B
22 Gasket, valve flat to head, dia 60 cyl. 1 00 04 1153 B
23 1” NRV kit 1 02 24 0313 9
24 "O" Ring, 31.34 x 3.53, DUV 1 00 05 1031 A
148
Kit spares
Kit No ............................................................................................... K 0206108

1 Filter Element assembly 2 00 03 1782 0
3 Ring, slotted oil control, Dia 100 2
4 Ring, stepped compression, Dia100 2 02 24 3413 9
5 Ring, Taper plain compression, Dia 100 1
6 Ring, slotted oil control, Dia 70
7 Ring, stepped compression, Dia 70 02 24 0104 9
8 Ring, Taper plain compression, Dia 70
9 Valve finger, Dia 90/100 Cyl. 8 00 03 3097 0
10 Valve finger, Dia 70 Cyl. 2 00 03 3096 0
12 Gasket, C/Case to Cylinder, 0.4 2 00 04 1004 B
13 Gasket, C/Case to Cylinder, 0.75 2 00 04 1004 C
17 ‘O’ Ring, Oil Level Indicator 1 00 05 2655 0
18 Rink, Packing, 17x22x2 1 00 05 2186 0
19 Ring, Packing, 30x38x2 1 00 05 2191 0
20 Ring, Packing, 33.5x38x3 2 00 05 2183 0
21 Ring, Packing, Head 3 00 05 2193 0
22 Valve Breather 1 00 05 1006 0
23 Gasket, Cyl. To Valve flat, dia 100 Cyl 2 00 04 1156 A
24 Gasket, Valve flat to Head, dia 100 Cyl 2 00 04 6210 A
25 Gasket, Cyl. To Valve flat, dia 70 Cyl. 1 00 04 1154 A
26 Gasket, Valve flat to Head, dia 70 Cyl. 1 00 04 1155 A
27 1" NRV Kit 1 02 24 0313 9
28 Diaphragm, Dia 86 x 3.5 PSW 1 00 05 1201 0
149
Kit spares
Kit, tune up, TS 10 120 HT, tank mounted for 2500 hours
Kit No ........................................................................................... 02 24 0248 9
S.No. Drg. /Part No. Description Qty.

1 A020436 VALVE ASSY BREA 1
2 000317820 ELEMENT FILTER 1
3 000411710 PKG RUBBER PSW 1
4 000415870 RING TPCDIA70 S 1
5 000415880 RING SC DIA70 S 1
6 000432220 SEAT DIA83xDIA1 2
7 00043442A SPRING SV 1/2"/ 2
8 000435920 SEAT VALVE SV 1 2
9 000512010 DIAPHRAGM DIA86 1
10 000919252 PLASTIC TUBING 1
11 020493900 REED VALVE ASSY 1
12 020494030 PLAIN RING DIA 1
13 020494040 RING SC DIA127 1
14 020494050 OIL RING EXPAND 1
15 020494060 OIL RING SEGMEN 2
16 020494070 RING OIL EXP TS 1
17 020494080 RING OIL SEG TS 2
18 020495560 SPRING, NRV 1 I 1
19 020495590 SEAT VITON BOND 1
20 022402519 Kit, Gasket TS 10 120 HT 1
SEAL OIL B45X60 1
RING PKG 17X22X 2
RING PKG 10.5X1 1
O RING OLI NRV 1
GASKET FLY END 1
GASKET 0.75C/CA 1
GASKET 0.75 C/C 1
GASKET 0.75 127 1
GASKET VALVE FL 1
GASKET FREE END 1
Gasket valve to Head 1
Gasket Cyl.to Valve 1
21 000330960 Valve Finger 2
22 000310040 Flat Valve 1
150
Kit spares
Kit, tune up, TS 10 120 HT, tank mounted for 1 year

Kit No ........................................................................................... 02 24 0310 9
S.No. Drg. /Part No. Description Qty.

1 A020436 VALVE ASSY BREA 2
2 A020464 FILTER ASSY I/L 4
3 00041843A NIPPLE HEX 1/2" 2
4 00043217A NIPPLE PIPE 1 1 2
5 00051887A PLUG HEX 1/8"BS 2
6 000521940 RING PKG 10.5X1 2
7 00052493A NIPPLE ROUND 1 2
8 000919252 PLASTIC TUBING 1
9 000920512 QUICK FITTINGS 2
10 000920612 QUICK FITTINGS 2
11 020490810 CONNEC TEE 1 1/ 2
12 020492460 REDU 1"X1/2"BSP 2
151
Kit spares
Kit No for 2500 Hrs ................................................................... K 02 06 109

1 Filter Element assembly 2 00 03 1782 0
4 Ring, stepped compression, Dia100 02 24 3413 9
7 Ring, stepped compression, Dia 70 02 24 0104 9
9 Valve finger, Dia 70 Cyl. 2 00 03 3096 0
10 Spring, Suction valve 2 00 04 1517 0
11 Plate, Suction Valve 2 00 04 1518 0
12 Plate, Disk Valve 2 00 04 1519 0
13 Spring, Disk Valve 4 00 04 1520 0
14 Gasket, big Cyl. To Disk valve 4 00 05 1921 0
15 Gasket, small Disk valve to Cyl. Head 2 00 05 1922 0
16 Pin, Disk Valve 2 00 05 1916 0
17 Plate, Bottom Suction valve 2 00 04 1516 0
23 Gasket, C/Case to Cylinder, 0.25 1 00 04 1002
152
Kit spares
Kit No for 2500 Hrs ................................................................... K 02 06 109

24 ‘O’ Ring, Oil Level Indicator 1 00 05 2655 0
25 Rink, Packing, 17x22x2 1 00 05 2186 0
26 Ring, Packing, 30x38x2 1 00 05 2191 0
27 Ring, Packing, 33.5x38x3 2 00 05 2183 0
28 Ring, Packing, Head 3 00 05 2193 0
29 Valve Breather 1 00 05 1006 0
30 Gasket, Cyl. To Valve flat, dia 70 Cyl. 1 00 04 1154 A
31 Gasket, Valve flat to Head, dia 70 Cyl. 1 00 04 1155 A
32 1" NRV kit 1 02 24 0313 9
33 Diaphragm, Dia 86 x 3.5 PSW 1 00 05 1201 0
35 Kit DUV cum Solenoid Valve 1 K02 06 076
153
Recommended Oil
Recommended Oil - Domestic Customers
1 Ltr Pack 3 Ltrs Pack
Specially formulated mineral oil for

Reciprocating Air Compressor
BPCL : PART No. 00 09 98 044 - 1 Ltrs

PART No. 00 09 98 052 - 3 Ltrs
IOCL : PART No. 00 09 98 056 - 1 Ltrs

PART No. 00 09 98 057 - 3 Ltrs
Recommended Oil - International Customers
Ambient temperature OC I.S.O. V.G. No.
-30 to –15 I.S.O. 32

-15 to +10 I.S.O. 68
+10 to +25 I.S.O. 100
+26 to +80 I.S.O. 150
Recommended grease for motor bearing
Bharat Hindustan
Indian Oil Castrol
Petroleum Petroleum
Wheel bearing Servo grease Ball bearing

Bharat univex A grease MP grease AP3
154
Recommended Oil
NOTE
Lubricating oil is filled into the compressor by
removing the breather assembly. Lubricating oil is
drained by unscrewing the drain plug. The electric
motor bearings should be lubricated by using a
special grease gun or by removing the end covers.
Performance Benifits :
# Specially formulated for reciprocating compressors with group 2
plus base oil.
# Minimizes wear & tear to running components
# Superior performance under severe load and high operating

temperatures
# Minimizes carbon deposits on valve components reducing risks of fire

and explosions
# Provides active protection against rust and corrision during shut down
# Excellent water seperation capacity
# Provides excellent resistant to oxidation
155
N O T E S
156
157
158
159
©
ELGI EQUIPMENTS LIMITED
Singanallur, Coimbatore, TN - 641 005, INDIA.
Part / Document No.
Revision Status
R00 - First Edition : May 2010
Replaces Earlier
Doc. No. : Nil

Date : Nil
Price : INR 750.00
Contact Info :
Coimbatore, TN - 641 005, INDIA.
Tel : 91 - 422 - 2589555

Fax : 91 - 422 - 2573697 (Domestic Business)
91 - 422 - 2576849 (International Business)
e-mail : info@elgi.com
www.elgi.com
HORIZON
ELECTRIC POWERED
RECIPROCATING AIR COMPRESSORS
RCD HAND BOOK

TWO STAGE, TWO CYLINDER
WITH DOL STARTER
TS03/05/07 120HN,
TWO STAGE, THREE CYLINDER

WITH DOL / STAR DELTA STARTER
TS10/15 120HN
&
TWO STAGE, TWO CYLINDER
WITH DOL / STAR DELTA STARTER
TS10 120HT
TANK MOUNTED
OPERATION AND MAINTENANCE MANUAL

PARTS MANUAL
List of Contents
CHAPTER-iI
PARTS LIST MANUAL
Reciprocating air compressor package
Reciprocating air compressor unit
Piston assembly
Inlet air filter assembly
Safety valve assembly
DUV / Solenoid valve assembly
Non-return valve assembly
Pressure switch assembly
Breather valve assembly
Reed valve assembly
Kit spares
Recommended oil
Maintenance chart
Test certificate / Packing slip
iv
162
List of Contents
CHAPTER-i
OPERATION AND MAINTENANCE MANUAL
User Information
Safety
Do’s and Don’ts
Specification and Salient features
Installation
System Operation
Functions of Vaious Systems
Safety and Interlocking Devices
Electrical Systems
Maintenance
Trouble Shooting
Recommended Spares
iii
163
Message from the Managing Director
Dear ELGI customer,
It gives me great pleasure to welcome you to the family of users of Horizon

compressors from ELGI, among the most sophisticated reciprocating air
compressors available in the world today.
ELGI has designed your Horizon 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 Horizon compressor optimally.
please familiarise yourself with all the information it contains.
I look forward to your continued satisfaction as a Horizon user. ELGI

honoured to be your choice for all your compressed air needs.
Yours sincerely,
Jairam Varadaraj
Managing Director
vi
164
Machine Identification and
Sale Record
Owner’s name :
Address :
Model :
FAB. No. :
Year of manufacturing :
Motor :
Capacity :
Rated Pressure :
Date of delivery :
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 and the dealer stamps and sign this page
v
165
Introduction
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 AND

PARTS MANUAL are receiving along with the compressor. 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 must 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.
viii
166
About ELGI
ELGI Equipments Limited, an ISO 9001 company, is the flagship of the ELGI
group. It has grown spectacularly over the last 45 years into a multi-market,
multi-product enterprise, transforming itself to meet the challenges of globalization.
ELGI is Asia’s largest and most integrated manufacturer of air compressors. It
is also a leader in automotive service equipment, with a comprehensive range
of products, and a manufacturer of diesel engines. The company has a strong
presence in the global market. It is one of the leading exporters in India, with
more than 30 percent of its production reaching endusers and OEMs in over 45
countries across the world.
ELGI operates out of two advanced and sophisticated manufacturing facilities

with R&D and CAD facilities, a totally integrated machine shop, CNC helical
rotor cutting machines, tool management centres, and a metrology laboratory.
ELGI’s dedication to after-sales service and support through its country-wide
system of branches and its global network of distributors and dealers has
earned it an excellent reputation. Driven by the philosophy of Think Long Run,
ELGI believes in forging long running partnerships with its customers and
partners world-wide guided by reliability, technology, capability and values and
fuelled by constant innovation.
vii
167
Users’ important information
In case of any requirements of spares or service, please contact our

nearest branch office or distributors
Due to improvements being made constantly and continuously, the

illustrations and descriptions on this manual are not binding.
SAFETY
IMPORTANT SAFETY INSTRUCTIONS FOR USE OF THE

COMPRESSOR.
WARNING
Death or serious bodily injury could result from
improper or unsafe use of compressor. To avoid these
risks, follow the basic safety instructions.
NOTE
Make sure this manual is read and carefully understood
before starting/ operating this machine.
Proof of purchase will be required for warranty
service.
x
168
Users’ important information
Read and understand all of the operating instructions, safety precaution and
warnings in the Instruction Manual before operating or maintaining this
compressor.
Most accidents that result from compressor operation and maintenance are
caused by the failure to observe basic safety rules or precautions. An
accident can often be avoided by recognising a potentially hazardous
situation before it occurs, and by observing appropriate safety procedures.
Basic safety precautions are outlined in the “SAFETY” section of this

Instruction Manual to be followed at most care to be taken through out the life
of the equipment.
Never use this compressor in a manner that has not been specifically
recommended by manufacturer, unless you first confirm that the planned
use will be safe for you and others.
Attend to any signs of minor irregularities immediately if neglected, they could

become worse.
Ensure the Operation Instruction Manual be made available to the

compressor operating personnel at all time.
While ordering spare parts the following particulars must be clearly

mentioned to ensure supply of the right spares.
1. MODEL
2. FAB NUMBER
3. YEAR OF MANUFACTURE
4. PART NAME
5. PART NUMBER
6. REQUIRED QUANTITY
ix
169
xii
170
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 Horizon
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 operating the

compressor.
xi
171
TEST CERTIFICATE FOR AIR COMPRESSOR
COMPRESSOR UNIT
Model : TANK
Fab. No. : Tank No. :

Motor Make :
Motor : 3.0 / 5.0 / 7.5 / 10 / 15 H.P Tank Capacity : Lts.
Motor No. :
Motor Speed : 1420 / 1430 / 1460 rpm Working Pressure : 12.0 Kg/cm 2
Starter Make : TC / BCH / L&T

Hyd.Test Pressure : 19.8 Kg/cm 2
Tested On :
Work pressure : 12.0 Kg/cm 2

Tested On :
Displacement : 302/501/700/1000/1235/1535 LPM
Compressor speed : 750 / 925 / 1050 / 1150 rpm
SETTINGS
Safety Valve Intercooler : 5.0 Kg/cm 2
Safety Valve Pressure line : 16.0 Kg/cm 2
Safety Valve for tank : 14.0 Kg/cm 2
Pressure Switch Cut In : 9.0 Kg/cm 2
Cut off : 12.0 Kg/cm 2
Starter - OLR 3 / 5 / 7.5 / 10 / 15 H.P : 5.2 / 8.2 / 11.5 / 15 / 13 Amps
Tested By : Q.A. In-charge :
PACKING SLIP
SI.No. Description Quantity
1. Top Block Assy. / Units : One

2. Direction Indication - anti-clockwise : One
3. Suction Filter : Two
4. Starter DOL / STAR DELTA Make : One
5. Pressure Switch Model : PSI - 15 1C Make : ELGI : One
6. "V" Belt Make & Size : : Two
7. Belt Guard : One
8. Shut Off Valve : Ball / Wheel Type : One
9 Delivery unloader valve & Silencer cum solenoid valve One
10 Motor pulley (for without elect.unit) One
11. Instruction & Maintenance Manual : One
12. Standard warranty card no. :
Inspected By : Date :
INSPECTION AND SERVICE RECORD
Scheduled date Results of inspection and outline of service

Date of Date of Inspected or
inspection completion of next inspection Oil Piston Ring & serviced by
of service and service Air valve Others
change Cylinder
174
175
176
177
Refer page no
43 & 44

TS - 03 - 05 - 07 - 10 - 15 - HN - TS10 - HT

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Do’s and Dont’s

! Read the manual in detail and follow the instructions.

! Clean the air compressor package regularly.

! Keep the air filter clean.

! Use only genuine spares.

! Maintain correct oil level.

! Use only clean, recommended lubricants.

! Use proper tools.

! Attend immediately to anything unusual with the air

! Maintain log book to monitor operation of compressor.

! Attend Repairs / Service with qualified technicians only.

" Neglect the routine attention.

" Allow any leakage in the system.

" Keep any tools or loose items on the compressor/other

" 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 eventhough it

Never touch moving parts

Never operate without all guards in place

Always wear eye protection

Always wear safety goggles or equivalent eye protection. Compressed

Protect yourself against hot spot

Prevent body contact with grounded surfaces such as pipes, cylinders,

Disconnect the compressor

Avoid unintentional starting

Do not carry the compressor while it is connected to its power source

Store compressor properly

Keep work area clean

Keep children away

Operate compressor at the rated voltage

Operate the compressor at voltages specified on their nameplates. If

Never use a compressor which is defective or

If the compressor appears to be operating unusually, making strange

Use only genuine replacement parts

Do not modify the compressor

Do not modify the compressor. Always contact the authorized service

Turn off the starter stop button to be latched

Maintain compressor with care

Follow instructions for lubricating. Inspect cords periodically and if

Before further use of the compressor, a guard or other part is damaged

Check for alignment of moving parts, binding of moving parts breakage

A guard or other part that is damaged should be properly repaired or

Handle compressor correctly

Operate the compressor according to the instructions provided herein.

Keep all screws, bolts and cover tightly in place

Keep all screws, bolts and plates tightly mounted. Electrical

Keep motor air vent clean

The correct rating of fuses to be provided at the incoming side of the

The correct rating of wires to be used for incoming connection and

Never take any loop lines from the compressor wiring.

02 Type Reciprocating, Air cooled, Splash lubricated

03 Displacement m3/h 18.16

04 Free air delivery @ 10 bar m3/h 15.00

05 Working pressure kgf/cm2 12

07 Compression stages No. 2

09 Cylinder size & stroke mm 70 x 50 x 85

10 Type of piston rings Dia 70 Dia 50

12 Type of valve Finger

14 Compressor speed rpm 925

15 Motor type Sq. cage Ind. TEFC

17 Motor speed - syn. rpm 1420

18 Motor frame size 100 L