Product Manual

Global Series
Diesel Powered Screw Air Compressor

PG 400 - 175 AC
WITH 6BTA ENGINE
©
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005

Part / Document No. 039000016

Contact Info:
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005, India
Tel : 91 - 422 2589555
Fax : 91 - 422 2573697 (Domestic Business)
Fax : 91 - 422 2589401 (International Business)
E-mail : [email protected]
Website : www.elgi.com
 Machine Identification and Sale Record

Owner’s name / : ………………………………………………………………………………………………………

Company name
………………………………………………………………………………………………………

Phone number : ………………………………………………………………………………………………………

Contact person : ………………………………………………………………………………………………………

E-Mail address/ : ………………………………………………………………………………………………………

Phone number
………………………………………………………………………………………………………

Model : ………………………………………………………………………………………………………

Fab. No. : ………………………………………………………………………………………………………

Year of manufacture : ………………………………………………………………………………………………………

Engine : ……………………………………………………………………………………………kW (HP)

Capacity : ……………………………………………………………………………………m3/min (cfm)

Rated pressure : ………………………………………………………………………………………bar.g (psi.g)

Date of delivery : ………………………………………………………………………………………………………

Date of commissioning : ………………………………………………………………………………………………………

Dealer name/address : ………………………………………………………………………………………………………

………………………………………………………………………………………………………

………………………………………………………………………………………………………

Dealer’s signature : ………………………………………………………………………………………………………

NOTE The warranty on the compressor is valid only if all the details above are filled in and the dealer stamps and signs
this page. This report must reach the Regional Office/Head Office of ELGi within seven days of commissioning
date.

1.5
 Owner Possession Information

Warranty book serial number : ………………………………………………………………………………………………………

Customer code : ………………………………………………………………………………………………………

Customer name : ………………………………………………………………………………………………………

………………………………………………………………………………………………………

Customer Address : ………………………………………………………………………………………………………

………………………………………………………………………………………………………

………………………………………………………………………………………………………

………………………………………………………………………………………………………

Contact data

Phone : ………………………………………………………………………………………………………

Mobile GSM : ………………………………………………………………………………………………………

Mobile CDMA : ………………………………………………………………………………………………………

Fax : ………………………………………………………………………………………………………

E-mail : ………………………………………………………………………………………………………

Compressor type : ………………………………………………………………………………………………………

Compressor model : ………………………………………………………………………………………………………

Fabrication number : ………………………………………………………………………………………………………

Invoice number : ………………………………………………………………………………………………………

Date of delivery : ………………………………………………………………………………………………………

Place of purchase : ………………………………………………………………………………………………………

Airend type : ………………………………………………………………………………………………………

Airend serial number : ………………………………………………………………………………………………………

Engine model : ………………………………………………………………………………………………………

Engine serial number : ………………………………………………………………………………………………………

1.7
Table of Contents

Chapter Page No.

1.0 About ELGi 1.9

2.0 General functional description 2.1

3.0 GA drawing, P&I diagram 3.1

4.0 Technical data 4.1

5.0 Installation and operation 5.1

6.0 Maintenance 6.1

7.0 Air inlet system 7.2

8.0 Drive system 8.1

9.0 Discharge system 9.1

10.0 Cooling system 10.1

11.0 Lubrication system 11.1

12.0 Trolley system 12.1

13.0 Canopy system 13.1

14.0 Control system 14.1

15.0 Instrumentation system 15.1

16.0 Spare kit details 16.1

17.0 Electrical drawings 17.1

1.8
 1.0 About ELGi

ELGi, established in 1960, designs and manufactures a wide range of air compressors. The company has gained its
reputation for design and manufacture of screw compressors through strategic partnerships and continuous research and
development. Over the years, it has emerged as a multi-product, multi-market enterprise providing total compressed air
solutions to all segments. ELGi’s design capabilities translated into a wide range of products ranging from oil-lubricated and
oil-free rotary screw compressors, reciprocating compressors and centrifugal compressors.

ELGi is one of the few companies in the world capable of manufacturing wide range of airends and compressor packages.
ELGi has most modern manufacturing facilities with high precision grinding machines, turning centres, CNC horizontal and
vertical machining centres and also the latest self measurement technology to maintain precise, aerospace manufacturing
tolerances. ELGi’s manufacturing plants are ISO and EOHS certified.

Over two million ELGi compressors are powering business in 70+ countries worldwide. The company offers a strong sales
and service network with a well-knit distribution network of dealers and distribution, worldwide. ELGi has its own
manufacturing operations in India, Italy and USA with subsidiary offices in Australia, Bangladesh, Brazil, China, Indonesia,
Italy, Malaysia, Middle East, Sri Lanka and Thailand. The company is fast expanding its global footprint, attracting
distributors and customers with its new generation products.

Need help…?

In India

You can contact ELGi customer care system (ECCS) to take care of customer complaints. The ELGi CCS works for six days a
week from 08:30 to 21:30 IST (Monday to Saturday). The complaints can be logged by calling any of the following toll free
numbers or by e–mail.

Toll free : 1800 425 3544

E-Mail : [email protected]
Website : www.elgi.com

Before making service request for your compressor, keep ready the details printed on the name plate of the compressor and
machine identification and sale record of this manual. When ordering spare parts, refer to the lists provided in the parts
manual and identify the part number. Specify the part number and quantity, in addition to the name plate details.

Refer “ELGi services” for more details about ECCS under chapter “Maintenance”.

1.9
 2.0 General functional description

Contents Page No.

2.1 Using the manual 2.2

2.1.1. Definitions and symbols 2.2

2.2 Introduction 2.3

2.3 Safety 2.4
2.3.1 Precautions during installation 2.4

2.3.2 Precautions during operation 2.5

2.3.3 Precautions during maintenance 2.7

2.4 Functional description 2.11

2.4.1 Air Flow 2.11

2.4.2 Oil system 2.11

2.4.3 Engine system 2.12

2.4.4 Regulating system 2.12

2.4.5 Safety and interlocking devices 2.12

2.4.5.1 Safety devices 2.12

2.4.5.2 Interlocking devices 2.13

General functional description 2.1

 2.1 Using the manual

This operation and maintenance manual has been specially

designed keeping you in mind so that you can get the
most out of your ELGi Global Series compressor. Before Warning calls attention to dangerous or hazardous
conditions inherent to the operation, cleaning and
you start using your compressor, do go through this maintenance of the compressor which may result in fatal
manual thoroughly. It contains vital information on accident and personal injury of the operator or other staff
operation as well as useful tips that will help you keep
your compressor running as good as new year after year.
It is essential to maintain the compressor as
recommended in the Maintenance section.
Caution is to draw attention to a procedure which, if not
The manual has been prepared with utmost care to help done correctly can lead to compressor damage.
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. ELGi reserves the right
to make changes in the product at any time without
notice.
The manual must be available at all times to the
personnel operating the compressor.

2.1.1 Definitions and symbols

This information is related to your safety and also to prevent

any problems relevant to the equipments used. To help

recognize this information better, the symbols are illustrated
in section “safety”.
All the information, illustrations and specifications in this
manual are based on the latest product information at the
time of preparation of the manual. Product improvement is a
continuous process in ELGi. The details in this manual are
likely to change without notice and ELGi reserves the right to
incorporate such changes.

NOTE
Note clarifies procedures or conditions which may otherwise
be misinterpreted or overlooked. Note may also be used to
clarify apparently contradictory or confusing situations.

General functional description 2.2

 2.2 Introduction

ELGI EQUIPMENTS LIMITED is a leading manufacturer of When ordering spare parts, refer to the list provided in this
rotary screw air compressors. ELGi’s rotary screw air manual and identify the part number. Specify the part
compressors are widely used globally. The equipment is number and quantity in addition to the name plate details.
known for their reliability, maintenance, friendliness and Salient features
safety. Every screw type air compressor is designed
keeping in mind three key quality considerations viz. Less maintenance

 Energy Efficiency A screw compressor has only two moving parts-the rotors
which do not touch each other as they are kept apart by
 Air Quality means of a thin film of oil and hence there is not wear and
 Maintenance tear. No reciprocating parts like piston, piston rings
connecting rod and no suction or discharge valves to be
We are confident that the equipment you have purchased maintained.
will give you satisfactory service for its life.
Maximum reliability
We thank you for giving us an opportunity to serve you
with our compressor. Please check and ensure OPERATION Only two moving rotors at conservative speed provide
AND MAINTENANCE MANUAL, PARTS MANUAL and ENGINE reliability never before attained in the history of the
MANUAL are received along with the compressor. compressor industry.

This Operation and Maintenance Manual has been specially Low discharge temperature
designed keeping you in mind, so that you can get the The heat of compression is taken away from the point of
most out of ELGi Compressor. Before you start using your origin to the cooler by the injected oil and hence discharge
compressor, do go through this manual thoroughly. It temperature does not exceed 90OC thereby no carbonized
contains vital information on operations and useful tips oil is formed in the compressor and in the system.
that will keep your compressor up and running.
Small package
All information, illustrations and specifications in this
Because of the unique way the screw compresses the air,
manual are based on the latest product development
a complete air package is provided in small overall
available at the time of supply. We reserve the right to
dimension with factory tested and ready to use condition.
make changes in the product at any time without notice.
We assure you of the best service in maintaining uptime of Vibration free & low noise
the compressor through prompt service and supply of There are no reciprocating masses. There are only rotating
spare parts as per your requirements. parts which are dynamically balanced.
Please read the instructions very carefully, right to the Long life
end, as the operating life and reliability of the compressor
Since there is no metallic contact between the rotors and
depends to a large extent on correct operation and
housing, rotors themselves and moreover they are flooded
maintenance.
with a strong flow of oil, no wear or reduction in output
While calling your ELGi branch office, dealer or service capacity/performance will occur even after many years of
centre regarding your compressor, keep at hand the operation.
details present on the name plate of the compressor and
No loss in capacity
the details entered in the inside front cover of this manual.
There is no wear in the solid steel screws providing no loss
General information in capacity of performance due to wear. The compressor
Your compressor belongs to a family of Global Series will provide the same air flow no matter whatever is its
rotary screw compressors from ELGi. Overall, the features age.
of your compressor translate to convenience for you. The Pulsation-free flow
compressor has only two moving parts—the rotors—which
are separated by a thin film of oil, so that there is no The continuous flow of air through the helical cavities in
wear. This also means that the reliability of the the screw and continuous compression ensures pulsation-
compressor is unsurpassed. free compressed air delivery.

The screw compressor technology ensures that there is no

reduction in output capacity even after many years of Air quality
operation. It involves a continuous flow of air through
The unique OSBID air-oil separation system provided
helical cavities in the screw and so the compressed air
ensures efficient separation of oil particles with a minimal
delivery is pulsation free.
pressure drop from the compressed air-oil mixture
The design of the Global Series gives you a compact and delivered at the compression end. The OSBID system
self-contained compressor. Because it has no reciprocating ensures consistent quality of air during normal running
parts, it runs quietly and free of vibrations. The discharge and unloading cycles.
temperature of the coolant oil is low, less than 90oC, and
Low operating cost
therefore carbonized oil is not formed in the compressor.
Screw compressor operating cost will be generally less
Please read the instructions in this manual carefully and
than other conventional machines.
follow them at all times. The operating life and reliability of
the compressor depend to a large extent on correct 2.2.1 Warranty information
operation and maintenance.
The company recommends that every ELGi compressor

General functional description 2.3

owner familiarize himself or herself with this warranty negligence or otherwise, including but not limited to loss
document. The warranty is explicitly/ implicitly subjected of profits of revenue, loss of total or partial use of the
to certain conditions. These are summarized here for the products, facilities of services, downtime costs or claims
benefit of the owners. of purchaser for such or other damages whether on
account of products furnished hereunder or delays in
The warranty is subjected to fulfilment inter alia of the
delivery there of will not be ELGi's liability.
following obligations by the purchaser/owner of the
compressor.  ELGi's liability on any claim, whether in warranty, strict
 Proper installation of the compressor. This is the sole liability, contract, tort, negligence or otherwise, for any
loss or damage arising out of, connected with or
responsibility of the purchaser.
resulting from this warranty or the performance or
 Normal use and preventive maintenance as breach thereof, or from the design, manufacture, sale,
recommended by the compressor owner’s operation delivery, resale, repair, replacement, installation,
manual supplied along with each compressor. technical direction of installation, inspection, serving,
 Warranty will be applicable subject to use of ELGi operation or use of any product covered by or furnished
genuine parts. under this warranty shall in no case exceed the
purchase price allowable to the product or part thereof
 Warranty as expressed/implied shall stand to exist only which gives rise to the claim.
when the equipment is registered with dealer/ELGi
plant.  Notice of claims against ELGi hereunder for any reason,
including breach of warranty, must be made to ELGi in
 In case any defects are noticed, it would be a writing within forty-eight (48) hours of discovery to
worthwhile effort on the owner’s part to satisfy himself afford ELGi the opportunity to make a prompt
or herself in the first instance that the defect could be investigation of the surrounding facts and mitigate any
reasonably deemed to be of workmanship or material damage which might ensue, should it be determined to
and that the compressor was never subjected to be ELGi's responsibility. Failure to give such notice to
conditions in respect of which the warranty has been ELGi shall constitute a waiver by purchaser of any right
expressly negated. later to assert such a claim.
 Any attempt to tamper with, or interchange any parts  Any cause of action against ELGi arising out of or
between, compressors shall void the warranty. The relating to the warranty or the performance hereof shall
company has a record of each compressor and parts expire unless brought within one (1) year of the time of
utilized thereon duly coded. actual thereof.
 Warranty claims related to the engine would be made  We provide warranty for the following equipment for a
directly to the engine manufacturer at their respective period of one year from the date of commissioning
regional centers only. This is in line with an agreement against defective material and bad workmanship and is
arrived between ELGi and the engine manufacturer. valid only when the product is used in accordance with
Refer to the engine manufacturer’s warranty conditions the manufacturer’s instructions as stated in the
(given along with the sale documents) as per Operation & Maintenance Manual.
international warranty terms and conditions.
1. Warranty does not apply to
 Engines, oil coolers, radiators, separator elements, etc.,
 Any compressor that shall have been subject to over
not manufactured by us are usually warranted by the
speeding, misuse, negligence or accident.
respective manufacturers. This shall however be
applicable as expressed/implied for warranty as per  If the compressor is not commissioned by ELGi/
manufacturer’s guidelines of maintenance/operation/ authorized person and duly not recorded in the
usage. Customer Maintenance Log Sheet.
 The maintenance of the equipment has to be strictly  Failures in any way resulting from use of parts not
logged in the log book and preserved, and the log book manufactured or approved by us.
shall be shown at any time when demanded by an ELGi
 Normal maintenance services including but, not limited
authorized representative.
to compressor tune up and the repair or replacement of
 To analyze the cause for compressor failure, or for any filters, compressor and other normal maintenance
major failure, the entire compressor package is to be spares.
brought to the place of service to be rendered, i.e.,
 The months/hours criteria would work on "whichever Is
factory or regional service center or dealer’s or agent’s
earlier" system from the date of invoicing the unit to the
premises.
original user.
 Used products, and products not assembled by Elgi, are
 The Commissioning of compressor shall be done only by
sold as is with no representation or warranty, and all
ELGi/authorized persons, after due verification of sale
warranties of quality, written, oral or implied, other than
documents of compressor and duly recorded in the log
may be expressly agreed to by ELGi's in writing,
book.
including without limitation, warranties of
merchantability or fitness, are hereby disclaimed.  Wherever Hour Meter reading is not available for
warranty claims determination, computation of total
 In no event shall ELGi be liable for special, indirect,
hour worked would be based on an average working of
incidental or consequential damages however arising,
10 hours per day from the date of invoice. In case,
whether in warrant, strict liability, contract, tort,
General functional description 2.4
 exclusion of downtime on account of major breakdown
is required, necessary documentary proof and log book
would be verified for the downtime claimed
 Warranty claims must be supported by purchase
vouchers for spares like Air filters/ Oil filters,
compressor oil etc., procured through ELGi outlet
Annexure V. This should correspond to the
recommendation of the manufacturer in terms of
quantity, interval of change and source of purchase and
proper recording to be maintained as per
Annexure/111.

 In respect of units working away from place of sale,

they should receive necessary service & spares on
chargeable basis, from the branch/ regional offices,
which is proximate to the working site of the unit.
Warranty claim should be filed with the branch who
made the sale along with purchase vouchers, service
report from branch/regional office which rendered
service and the failed components should be sent to the
Head Office located at M/s. ELGi Equipments Limited,
Trichy Road, Singanallur, Coimbatore - 641 005 within
a period of 15 days from the date of service report. Any
warranty claim made beyond this stipulated time,
would not be entertained. The statutory levies so
incurred during part replacement shall not be refunded
when considered for warranty.
 We make no warranty as to normal wear and tear, nor
do we agree to be liable for loss of time to the used
while the compressor or other equipment is out of
commission, nor for any labour or other expense,
damage or loss occasioned, or claimed to be occasioned
by such defective parts.

 Any claim or obligation in connection with the sale of

our compressor shall be subject to the jurisdiction of
the courts in Coimbatore.
 The Company make no warranties expressed or implied
relating to the sale of ELGi's genuine replacement
parts.
 The Companies warranty practice with respect to
allowances made for material, labour or miscellaneous
expenses associated with the repair of a failure
involving genuine ELGi's replacement parts is beyond
the Company's legal obligation.

General functional description 2.5

 2.3 Safety

The operator must follow the safe working practices, coolant temperature is below its boiling point. Loosen
instructions, procedures that this manual describes for the cap slowly to relieve any excess pressure and make
safe operation. The maintenance personnel must be sure that the coolant is not boiling before removing the
adequately trained, and have read and thoroughly cap completely.
understood this ‘Operation and maintenance manual’.  Manually pop up the pressure relief valve when the
Decals are affixed at specific locations of the compressor compressor is operating, at least weekly, to make sure
and they illustrate very important safety precautions. the pressure relief valve is not blocked, closed,
2.3.1 Precautions during operations obstructed or otherwise inoperative.

 Never start air compressor unless it is safe to do so. Do  After stopping the engine, confirm that the pressure
not attempt to operate the air compressor with a known gauge indicates 0 bar and before starting repair and
unsafe condition. Tag the air compressor and render it maintenance. Residual air under pressure will blow off
inoperative by disconnecting power supply so others and severely injure the operator.
who may not know of unsafe condition will not attempt  Under any circumstance, do not open the oil fill cap of
to operate it until the condition is corrected. the separator receiver tank while running or
 This Elgi screw compressor is not explosive-proof and is immediately after stopping operation. It is very
not to be operated in explosive areas. dangerous because the oil filler could be blown off and
high temperature compressed air and oil could jet out
 Do not modify the compressor except with written from the filler port and cause serious injury.
factory approval.
 When you refill the separator receiver tank with
Pressure release compressor oil, stop the engine and make sure that the
pressure gauge indicates 0 bar and that there is no
 Do not use tools that are rated below the maximum
residual pressure in it, and then gradually loosen the oil
rating of this compressor. Select tools, air hoses, pipes,
filler cap for refilling oil.
valves, filters and other fittings accordingly. Do not
exceed the manufacturer’s rated safe operating Fire and explosion
pressure for these items.
 Clean up spills of lubricant or other combustible
 Secure all hose connections by wire, chain or other substances immediately if spills occur.
suitable retaining devices to prevent tools or hose ends
from being accidentally disconnected.  Shut off the air compressor and allow it to cool. Keep
sparks, flames and other sources of ignition away and
 Open the oil fill cap only when the compressor is not do not permit smoking in the vicinity when checking or
running and is not pressurized. Shut down the adding oil/fuel.
compressor and bleed the receiver tank to zero internal
pressure before removing the cap.
 Vent all internal pressure prior to opening any line,
fitting, hose, valve, drain plug, connection or other
component, such as filters.

 Keep personnel out of line with and away from the  Do not use flammable solvents for cleaning purposes.
discharge end of hoses or tools or other points of  Keep electrical wiring and other terminals in good
compressed air discharge. condition. Replace any wiring that has cracked, cut,
abraded or otherwise degraded insulation; keep all
terminals clean and tight.
 Keep grounded conductive objects such as tools away
from exposed live electrical parts such as terminals to
avoid arcing, which might serve as a source of ignition.
 Keep oily rags, trash, dry leaves, litter or other
combustibles out of and away from the compressor.
 Do not operate the compressor without a proper flow of
cooling air/ cooling water or with an inadequate flow of
lubricant or with a degraded lubricant.
 Do not attempt to operate the compressor in any class
of hazardous environment unless the compressor has
been specially designed and manufactured for explosive
 Do not use air at a pressure higher than 2.5 kg f/cm2 applications.
for any cleaning purposes.  Disconnect the grounded (negative) battery connection
 Do not engage in horseplay with air hoses as death or prior to attempting to any repairs or cleaning inside the
serious injury may result. compressor enclosure.

 Do not remove the radiator pressure cap until the  Tag the battery connection cable so that others will not
accidentally reconnect it.

General functional description 2.6

 Switch off the battery charger before making or parts during any checking/testing.
breaking connections to the battery.  Do not attempt to operate the compressor with the fan,
 Keep flames away from the battery because the battery coupling or other guards removed.
may generate hydrogen gas and may explode.  Wear snug-fitting clothing and confine long hair when
 Under any circumstance, do not bring lit cigarettes or working around the compressor, especially when hot or
matches near such oils as engine oil and compressor oil. moving parts are exposed.

 Replace damaged fuel tanks or lines immediately rather  Keep access doors, if any, closed except when making
than attempting to weld or otherwise repair them. Do repairs or adjustments.
not store or attempt to operate the compressor with any  Make sure all personnel are out of and/or clear of the
known leaks in the fuel system.
compressor prior to attempting to start or operate it
 Such parts as mufflers and exhaust pipes can be
extremely hot. Remove twigs, dried leaves, dried grass,
waste paper, etc., from the exhaust outlet of the
muffler.

 Be sure to perform periodical checks of the compressor

oil and oil separator. Neglecting checks could cause
overheating of the oil, resulting in a fire.
 Open all the access doors and ventilate the enclosure
prior to attempting to start the engine.
 Have fire extinguishers near the unit, ready for  Disconnect and lock out all power at source and verify
emergency situations. at the compressor that the circuits are de-energized to
minimize the possibility of an accidental start-up or
Battery Safety
 Never wash the battery with pressurized water.
 Never top up with acid/mineral water/tap water/stream
water.

 Never apply grease on terminals/cable clamps.

 Never remove electrolyte, and never overfill the

battery.

 Never hammer down the clamps on the terminals.

 Never operate the vehicle or charge the battery if the
electrolyte temperature exceeds 60°C.

 Never short the battery terminals directly with a cable.

 Never do any welding work while charging.

operation, prior to attempting repairs or adjustments.
 Never allow the batteries to run the vehicle with the
This is especially important when the compressor is
specific gravity below 1.19.
remotely controlled.
 Never operate vehicles with batteries of two different
 Keep hands, feet, floors, controls and walking surfaces
specific gravity values.
clean and free of fluid, water or other liquids to
 Never run vehicles with the vent plugs open. minimize the possibility of slips and falls.
 Never recharge the battery without topping up to the  Make adjustments only when the engine is shut off.
maximum level.
 Keep hands away from rotating parts or belts. If hands
 Do not connect any other power connections for local are caught they can be seriously injured.
lighting/rig lighting or any other purpose from this
battery connection.
Hot surfaces
Decals are fitted on the exposed hot surfaces of the
Moving Parts
compressor.
Decals are fitted on the compressor to identify
 Avoid bodily contact with hot oil, hot coolant and hot
moving rotating parts.
surfaces.
 The compressor is designed for running with the
 Keep all parts of the body away from all points of air
enclosure doors closed. Ensure that no loose parts are
discharge.
kept inside and that all doors are closed before starting
the compressor.  Wear personal protective equipment including gloves
and head coverings when working in, on or around the
 Keep hands, arms and other parts of the body as well
compressor.
as clothing away from couplings, fans and other moving

General functional description 2.7

 Keep a first-aid kit handy. Seek medical assistance  Keep the towing vehicle or equipment carrier,
promptly in case of injury. Do not ignore small cuts and compressor, hoses, tools and all personnel at least 10
burns as they may lead to infections. feet from power lines and buried cables.
 After stopping the engine, wait for 10 to 20 minutes  Disconnect, lock out and tag all the power lines prior to
until the engine oil cools down. Then check the level of attempting repairs or adjustments to the machinery and
the engine oil, or refill or drain the oil. Engine oil is very prior to handling any ungrounded conductors.
hot and highly pressurized during or just after
operation. This hot oil could blow out of the tank and
Lifting

can cause scalding.

Toxic and irritating substances  The compressor is provided with a lifting bail (“2”).
Ensure the compressor is lifted using the lifting
 Do not use air from this compressor for respiration provided. Use slings of adequate capacity to lift the
(breathing). compressor for lifting above 3 metres from ground level
 Exhaust gas from the engine is poisonous and could or to transport the compressor using a helicopter.
cause death when inhaled. Avoid using the machine in  Prior to lifting, inspect the lifting bail and points of
an insufficiently ventilated building or tunnel. attachment for cracked welds and for cracked or bent or
 Oils, coolants and lubricants used in this compressor are corroded or otherwise degraded members and for loose
typical of the industry. Care should be taken to avoid bolts or nuts.
accidental ingestion and/or skin contact. In the event of  Make sure that the entire lifting, rigging and supporting
ingestion, seek medical treatment promptly. structure has been inspected, is in good condition and
 Wash with soap and water in the event of skin contact. has a rated capacity of at least the net weight of the
compressor plus an additional 10% allowance for the
 Never blow compressor air directly to people. Scattered weight of mud or stored tools and equipment. Weigh
impurities, dust and foreign objects in the compressed the compressor if you are not sure of the total weight.
air may cause skin and eyes to be seriously injured.
Towing the trolley
 When the machine has to be unavoidably temporarily
operated with its port open, be sure to mount a silencer A) Preparation
to reduce noise and wear protective materials such as
 Inspect the air compressor ball hitch, pintle eye or other
ear plugs to prevent damage to hearing.
coupling device, drawbars and chains if provided, and
Electric shock also the towing vehicle coupling device for defects such
as excessive wear or corrosion, cracks, deformed or
 Keep all parts degraded members and loose nuts, bolts and other
of the body and fasteners.
any hand-held
tools or other

conductive objects away from exposed live parts of the

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

 Attempt repairs only in clean, dry and well-lit and

ventilated areas.  Manoeuvre in a manner that will not exceed the

General functional description 2.8

 freedom of motion of the compressor’s drawbar and  Avoid potholes, rocks and other obstructions and soft
coupling device in or on the towing vehicle’s coupling shoulders or unstable terrain.
device and adjacent structure, whether towing forwards
 Do not permit personnel to ride in or on the
or backwards, regardless of the terrain being traversed.
compressor.
 Back the towing vehicle to the compressor trolley and
 Make sure that the area behind and under the
position it in preparation for coupling the compressor.
compressor is clear of all personnel and obstructions
 Make sure that all access doors and tool box covers are prior to packing.
closed and latched. If the compressor is large enough to
 Do not permit personnel to stand or ride on the drawbar
hold a man, ensure the exit before closing the doors
or to stand or walk between the compressor and the
latches.
towing vehicle.
 Make sure that the parking brakes in towing vehicles
are set, or that their wheels are choked or blocked, or C) Parking or locating compressor
that is otherwise restrained from moving. Then release  Park or locate the compressor on levelled area, if
the compressor parking brakes, if provided. possible. If not, park or locate compressor across the
 Test the operation of running brake wherever provided gradient, so that the compressor does not tend to roll
before attempting to tow the compressor at the downhill. Do not park or locate the compressor on a
permissible speed. land gradient exceeding 15° (27%).

 Prior to lifting, inspect lifting bail and points of  Make sure that the compressor is parked or located on a
attachment for cracked welds and for cracked or bent or firm surface that can support its weight.
corroded or otherwise degraded members and for loose
bolts or nuts.

 Make sure entire lifting, rigging and supporting

structure has been inspected, is in good condition and
has a rated capacity of at least the net weight of the
compressor plus an additional 10% allowance for the
weight of mud or stored tools and equipment. Weigh
the compressor if not sure of the total weight.
 Make sure lifting hook “1” has a functional safety latch,
or equivalent and it is fully engaged & latched on the
lifting bail.

 Do not attempt to lift in high winds.

 Keep all the personnel away from under and away from
the compressor when it is suspended.
 Do not lift the compressor higher than necessary.

 Keep lift operator in constant attendance when  Park compressors such that the wind tends to carry the
compressor is suspended. exhaust away from personnel and away from the
 Set compressor down only on level surfaces capable of compressor air inlet openings, and where the
supporting at least its net weight plus an additional compressor will not be exposed to excessive dust from
10% allowance for the weight of mud or stored tools the work site.
and other equipment.  If provided, unhook chains and remove them from the
B) Towing points of chain attachment on the towing vehicle; then
hook the chains to the ball on drawn bar and hook them
 When towing unit, make sure that there is no person or to themselves to keep the chains off the ground which
obstacle at both the front and the rear sides and under might accelerate rusting.
the unit.
 If provided, lower front screw lock and/or any rear
 Observe all traffic laws, including those specifying the stabilizer legs. Make sure that the surface they contact
minimum speed. has sufficient load bearing capability to support the
 Tow at an appropriate speed as listed below, or less, weight of the compressor.
under ideal conditions.  Keep feet clear of the drawbar at all times to avoid
Safe speed limit is maximum 30 Km/hr crushing accidents in case it should slip from your hands
or otherwise fall to the ground.
Speed variations allowed as per road conditions.
 Move the towing vehicle well clear of the parked
 Remember that the portable air compressor may
compressor and erect hazard indicators, barricades and/
approach or exceed the weight of the towing vehicle.
or flares (if at night) if compressor is parked on or
Maintain increased stopping distance accordingly.
adjacent to public roads.
 Avoid grades in excess of 15° (27%).

General functional description 2.9

2.3.2 Do’s and don’ts
Do’s
 Read the manual in detail and follow the instructions

 Clean the air compressor package regularly.

 Keep the air filter clean.

 Use only genuine elgi spares.

 Use only clean and recommended lubricants.

 Maintain the correct oil level.

 Use proper tools.

 Attend immediately to anything unusual relating to the

air compressor.

 Maintain a log book to monitor the operation of the

compressor.

 Attend to repairs/service with qualified technicians only.

 Please check that the exhaust line flap is closed

properly after shut down.
Don’ts

 Neglect routine attention.

 Allow any leakage in the system.

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

modules.

 Meddle with any adjustments or settings.

 Use cleaning agents when changing oil.

 Do any repair work while the unit is running.

 Overload the compressor for a long period, even though

it is of continuous rating.

General functional description 2.10

 2.4 Functional description

ENGINE AIR FILLTER HOT WATER PIPE

ENGINE AIR FILLTER DUCT RADIATOR
AIR FILLTER CHOKE INDICATOR
COMPRESSOR
COMPRESSOR
AIR FILTER
AIR FILTER OIL COOLER

PULSE LINE TUBE TO INTAKE

SCAVENGING OIL
PIPE

AIR OIL
OIL FILTER
MINIMUM
PRESSURE VALVE
PRESSURE RELIEF
VALVE

THERMAL VALVE
ASSY

OIL STOP
VALVE COLD WATER PIPE
OIL COOLER INLET PIPE
DISCHARGE
CHECK VALVE OIL COOLER
OUTLET PIPE

ENGINE ACTUATOR

PULSE LINE ACTUATOR

OUTLET BALL
VALVES ENGINE
INTAKE VALVE

AIR-END

CONTROL PANEL

Figure 2.1 Regulating systems

2.4.1 Airflow system outlet valves are open. This ensures adequate oil injection
and prevents oil carry consumption / oil carry over.
The system comprises
Blow down valve provided in the tank, to automatically
 AIRFILTER (AF) depressurize the air from the received when the
compressor is stopped. Temperature switch /gauge and
 BUTTERFLY VALVE / INTAKE VALVE (BFV/IV) pressure gauge incorporated in the system.

 AIREND(AE) 2.4.2 Oil system

 DISCHARGE CHECK VALVE(DCV) The system comprises

 AIR RECEIVER (AR)  AIR RECEIVER (AR)

 AIR - OIL SEPARATOR (AOS)  OIL COOLER(OC)

 MINIMUM PRESSURE VALVE(MPV)  OIL FILTER(OF)

 BLOW DOWN VALVE(BDV)  THERMAL VALVE(TV)

The air drawn through the air filter into the airend through  OIL STOP VALVE
butterfly valve / intake valve is compressed. The air-oil
Oil stored in bottom of the air-receiver, air pressure forces
mixture is delivered through air-receiver through discharge
the oil from the air-receiver through the oil cooler and oil
check valve. It prevents the oil back flow of compressed
filter to the airend.
air when the compressor is stopped.
The airend has an oil injection port, whereas for rotor
In the air receiver tank , most of the oil is removed from
lubrication, cooling and sealing purpose oil is injected
the air/oil mixture, the remaining oil removed by the air-
through that port from air-oil separator element through
oil separator element. The oil collects in the bottom of the
scavenging line (with strainer).
receiver and on the bottom of the separator element.
The injected oil mixed with compressed air leaves the
The air leaves the receiver through Minimum Pressure
airend and re-enters the air receiver, where it is separated
valve (MPV) which prevents the tank pressure dropping
from the air.
below the minimum working pressure, even when the air

General functional description 2.11

The oil filter by-pass valve opens when the pressure drop
over the filter is above normal because of clogged filter
leads to bypass the oil to airend without filtration.
For this reason, the oil filter must be replaced at regular
intervals.
Oil stop valve provided in this circuit to allow oil from
cooler once compressor starts and must not allow oil from
cooler once compressor stops
Thermal valve provided in this circuit to maintain minimum
temperature of oil greater than pressure dew point
temperature to avoid condensation.

2.4.3 Engine system

The system comprises

 ENGINE
 The ammeter fitted in the panel shows the condition of
the battery.
 FAN
 The discharge temperature gauge reading is taken
 RADIATOR from the discharge line. The maximum allowable
temperature of the discharge air-oil mixture is 110°C in
 CHARGED AIR COOLER (AS RECOMMENDED BY ENGINE the case of a mineral oil. This gauge indicates the
SUPPLIER) overall system temperature.
The engine which drives the airend with drive coupling
 The isolator is fitted on the panel for safety.
arrangement. Axial fan provided in engine to cool the
coolant flow in radiator and compressed air which flows  The air filter indicator for the compressor and engine
through charged air cooler. Turbocharged engines are not is fitted at the point of entry of air to the filter
provided with charged air-coolers. assembly. This indicates the condition of the air filter.
When the air filter is choked the red-coloured stem
2.4.4 Regulating system
moves forward and provides an indication that cleaning
The system comprises is required. This also provides an idea of the restriction
level of the air filter element so that maintenance can
 PRESSURE REGULATOR
be carried out accordingly (either replacement or
 BUTTERFLY VALVE cleaning).

 MOISTURE SEPARATOR  The engine oil temperature gauge is fitted at the oil
sump of the engine. This indicates the engine oil
 ACTUATOR temperature. This switch is set at 120°C, and when the
engine oil temperature exceeds 120°C the unit trips
The engine lever and butterfly valve is throttled by the
automatically.
actuator which in turn gets the input air from the receiver
tank through the pressure regulator and moisture  The engine oil pressure gauge is fitted at the engine
separator. oil sump block to indicate the oil pressure inside the
2.4.5 Safety and interlocking devices sump.

2.4.5.1 Safety devices  The engine water temperature gauge indicates the
temperature of the water cooling the engine.
 The oil level indicator of the compressor is fitted at
the compressor sump (separator tank). This indicates  The hour meter measures the running hours of the
the oil level in the sump before the unit is started. engine.
When the machine is running, the oil level may not be
readable.  The manifold pressure gauge of the airend is fitted at
the oil line manifold (near the bearing oil filter line) to
 The discharge temperature switch is fitted on the indicate the pressure of the oil going to the bearings of
panel. It shuts down the compressor if the discharge air both airends
-oil mixture temperature reaches the preset value of
2.4.5.2 Interlocking devices
115OC. The probe is fitted on the DCV adaptor.
The following interlocking devices have been provided your
 The line pressure gauge reading is taken from the dry compressor for safe and reliable service.
air from the sump top plate. This indicates the line
The minimum pressure valve is fitted at the outlet of
pressure in all operation modes.
the oil separator. It maintains a minimum receiver tank
 The sump pressure gauge reading is taken from the pressure of about 4kgf/cm2 during all conditions, which
wet side of the sump. This indicates the sump pressure facilitates proper air-oil separation and circulation of oil to
in all operation modes. the airend.

General functional description 2.12

The oil stop valve is located downstream of the bearing thereby controlling the amount of intake air of the airend.
oil filter and upstream of the airend. It cuts off the oil It also operates the engine governor lever to increase/
supply to the compressor unit when the unit is shut down. decrease the engine speed according to the demand.
The pressure regulator valve can be adjusted The blow down valve installed in the receiver tank
depending upon your pressure requirements. It is set to serves two functions:
supply a pressurized air pulse to the single acting actuator, When the compressor starts up, the air pulse line from the
which in turn operates the butterfly valve to gradually
outlet opens, which in turn closes the blow down valve to
open or close the inlet port of the airend, in accordance permit the air-oil pressure to build up in the air-oil receiver
with the outlet air pressure at suction. It also operates the
tank. When the machine is shutting down, the air pulse
engine governor lever to vary the speed between 1100
rpm (idle) and 2100 rpm, or the rated speed, according to
the air demand.

OUT

IN
OUT

Figure 2.4 Pressure regulator valve

IN line from the outlet closes, which in turn opens the valve
to bring the tank pressure down to atmospheric.
Figure 2.2 Minimum pressure valve
The discharge check valve is used for automatically
limiting the flow in a piping system to a single direction.
An actuator connected to the butterfly valve opens the
This (non-return) valve is installed between the airend and
butterfly valve or closes it gradually in response to the the separator tank inlet point to allow the air-oil to flow in
pressure signal received from the pressure regulator valve,

IN
Figure 2.5 Actuator

one direction alone so that the air filter is protected from a

sudden reverse flow of the air-oil mixture from the
receiver tank when the unit trips. When the machine is
running, the air-oil mixture moves from the airend outlet
to the air-oil receiver tank.

Figure 2.3 Oil stop valve The thermal valve allows the oil to flow from the receiver
tank to the oil filter when the temperature is less than or

General functional description 2.13

equal to the "start to move temperature". It also bypasses
the oil to the oil cooler when the temperature is above the
"cracking temperature". This maintains the dew point

Figure 2.8 Thermal valve

Figure 2.6 Blow down valve

temperature of the whole cooling system.

Figure 2.7 Discharge Check Valve

General functional description 2.14

 4.0 Technical data

No. Description Unit Data

01 Model PG 400-175 AC

02 Duty cycle Intermittent Duty

3
03 Free air delivery ( Max ) cfm (m / min) 400(11.33)

04 Maximum working pressure (g) bar (kgf /cm²) 12.00(12.2)

05 Idling pressure (g) bar (kgf / cm²) 13.00(13.3)

06 Engine make CUMMINS

07 Engine model 6BTA

08 Engine power output - Net HP 169

09 Rated operating speed rpm 2100

10 Idling speed rpm 1250

11 Fuel consumption at rated condition Ltr / hr 32

12 Engine lube oil capacity Litres

13 Engine coolant capacity Litres 35

14 Battery capacity and quantity AH & Nos 120 x 2nos

15 Flywheel housing SAE 3

16 Flywheel SAE 11.5

17 Fan type and diameter mm ( inch) PUSHER,813(32)

18 Maximum - ambient and altitude °C & m 5 to 50 and 3048

19 Type of Mounting TROLLEY-2W

20 Recommended maximum trolley speed Km / h 30 max

ELGI AIR LUBE / AIR LUBE PLUS / AIR LUBE

21 Oil recommended
XD

22 Capacity of separator tank ( full volume) Litres 65

23 Oil fill capacity Litres 27

24 Initial oil fill /refill Litres 17/10

25 Fuel tank capacity Litres 200

26 Air outlet port size & Qty. Inches & Nos 1 1/2"-1No, 3/4"-4 Nos

Skid / Without
Overall dimensions mm 3075 x 1340 x 1810
27 under carriage
max (L x B x H)
With under carriage mm 3885 x 1860 x 2175

28 Net Weight (Dry condition) kg 2110(Approx)

29 Reference standard for FAD and SFC ISO 1217:2009 Annexure 'D'

30 Reference standard for noise level ISO 2151, Second Edition

Technical data 4.1

 5.0 Installation and operation

Contents Page No.

5.1. Installation and commissioning 5.2
5.1.1 Handling the compressor 5.2

5.1.2 Compressor location 5.2

5.1.3 Installation requirements 5.3

5.1.4 Commissioning procedure 5.3

5.1.5 Pre-shipment procedure for compressor stored for more than six months 5.5

5.2. Preservation for long idle storage 5.6

5.2.1 Airend 5.6

5.3. Operating instructions 5.7

5.3.1 Pre starting checks 5.7

5.3.2 Starting the compressor 5.7

5.3.3 START - STOP procedure 5.8

Installation and operation 5.1

 5.1 Installation and commissioning

Nomenclature of models compressor depend to a large extent on correct operation

and maintenance.
PG S – Portable Global -Skid Mounted
When communicating with ELGi dealer/service center/
PG – Portable Global -Trolley Mounted
branch office regarding the compressor you have, ensure
EXAMPLE: all the details on name plate are given. The name plate is
PG 500S-175 fitted on the side of the compressor canopy. For ordering
spare parts, refer “Recommended Spare Parts” chapter
P – PORTABLE
and provide part number along with quantity in addition
G – GLOBAL-Trolley type to the name plate data of compressor.
500 – FAD in cfm
5.1.1 Handling the compressor
175 – Pressure value in psi (g)
1. Lift the compressor using the lifting bail.

2. Prior to lifting, inspect the lifting bail and points of

attachment for cracked welds and for cracked, bent,
corroded or otherwise degraded members and for loose
bolts and nuts.

3. Make sure the lifting hook has a functional safety latch,

or equivalent, and is fully engaged and latched on the
bail.

4. Use guide ropes or equivalent to prevent twisting or

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

5. Do not attempt to lift in high winds.

6. Keep all personnel out from under and away from the
PG 185-100 compressor when it is suspended.

P – PORTABLE 7. Lift compressor no higher than necessary.

G – GLOBAL-Trolley type 8. Keep lift operator in constant attendance whenever

compressor is suspended.
185 – FAD in cfm
100 – Pressure value in psi (g)
5.1.2 Compressor location
 Please observe the valid accident prevention regulations
when installing the compressor.

 Install the compressor with adequate accessibility to

ensure obstruction-free operation and maintenance.

 The area around the compressor should be clean, dry,

cool and free of dust.

 Excessively warm intake air affects the compressed air

output. The ambient temperature should not drop below
0°C.

 When the ambient temperature is below 0°C, the

compressor should not be operated. For assistance/
clarifications on cold start kits and other arrangements,
ENSURE THE COMPRESSOR IS LIFTED BY USING please contact ELGi India.
THE LIFTING BAIL ONLY.
 ENSURE THAT THE COMPRESSOR IS LIFTED USING THE
A NORMAL LEAK DUE TO METAL TO METAL SEALING LIFTING EYE PROVIDED ON THE LIFTING BAIL ONLY.
NEAR THE THERMAL EXPANSION JOINTS IS
 Ensure that this operation manual is made available at
NORMAL. THIS WILL NOT AFFECT THE
all times to the personnel operating the compressor.
PERFORMANCE OR RELIABILITY OF THE MACHINE.
 Please read the instructions carefully and strictly adhere
Ensure that this operation manual is made available at all
to them as the operating life and the reliability of the
times to the personnel operating the compressor.
compressor depend to a large extent on correct
Please read the instructions carefully and strictly adhere it operation and maintenance.
to the end as the operating life and the reliability of the

Installation and operation 5.2

 When communicating with an ELGi dealer/service 5.1.3.2 Electrical connection
centre/branch office regarding your compressor, ensure
Ensure authorized electricians only carry out the
that all the details on the name plate (format shown
electrical work. Study the electrical circuit diagram
below) are given. The name plate is fitted on the front
before starting work.
of the compressor base frame. For ordering spare parts,
refer to the Recommended Spare Parts section and  The batteries suppli ed along with the compressor are
provide the part number along with the required not charged. Ensure that the batteries are removed
quantity in addition to the name plate data of the from the unit, prepared suitably and charged.
compressor.  The electrical connections in the compressor are
5.1.3 Installation completed and tested at the factory before shipment.
The wiring circuit diagram is supplied along with the
General compressor. Study the wiring diagram before
The operating instructions given below are for connection.
commissioning standard version air-cooled series
 Fix the batteries in position (after charging) and secure
compressors without additional equipment. Before
them. Connect the cables to the batteries as per the
commissioning the equipment, check for visual damages of
wiring diagram.
parts. An electrical circuit diagram is delivered with every
compressor for electrical wiring reference. Every screw  Check the correctness of the connections with a multi-

compressor is subjected to a test run and set prior to meter and then by switching-on the lamp in the

despatch. Transport damage at a later stage cannot compressor.

however be excluded. Therefore, please observe the  Remove the battery connection when the compressor is
compressor closely during commissioning and trial run. not prepared for starting. This is to ensure accidental
starting by unauthorized personnel/personnel unaware
5.1.3.1 Installation requirements
of the state of the compressor.
While installing the compressors, ensure the following:
5.1.4 Commissioning process
 Compressor is kept on a levelled surface capable of with
standing the weight. Before the new Global Series compressor is operated for
the first time, it needs to be installed at your site
 Safe operation of the compressor is only ensured if the
according to ELGi’s specifications. ELGi’s commissioning
ambient temperature remains within the limits.
engineer carries out a series of checks on the machine and
 Forced cool airflow should not be directed towards the the systems to which it is connected to ensure that it is in
compressor. a condition to function safely and as desired. The engineer

 Compressor to be located such that hot air from other will then describe to the operator of your compressor how
machines is not directed the compressor. the equipment is to be operated and maintained. This
procedure is referred to as commissioning process. The
 Keep the compressor under cover to protect from rain/
commissioning of your compressor ensures that it is
storms.
installed safely: the general operating conditions of the
 Keep clearance space of 1.5 meters around the equipment such as the cleanliness of the atmosphere,
compressor. temperature and ventilation are checked. Technical details

 The battery supplied along with compressor package is relating to your system such as particulars of your
electrical installation are noted. The operator of your
not charged. You need to charge the batteries for 72
compressor is familiarized with all aspects of both its
hours before commissioning.
normal running and dealing with unusual situations. The

NOTE commissioning process provides to ELGi data that will help

understand your requirements better. Please make
If you fail to observe the instructions concerning
installation and ventilation, the discharge temperature of preparations for commissioning your Global Series
the compressor may increase or decrease excessively and compressor according to the instructions provided in the
trip-off the compressor at high discharge temperature Installation section of this manual.
conditions. The output of the compressor will also be
affected. Ensure that the location chosen meets the requirements of
accessibility, ventilation and safety. Upon completion of
NOTE the commissioning process, the commissioning engineer
The compressor will not give warnings during short will fill in a document known as the commissioning report.
operating times. It will operate below dew point and Please verify the information filled in and attest the
moisture condensate will mix with oil. This will reduce the
certificate of completion of commissioning. The ELGi
lubricating qualities of oil and lead to damage to the
compressor commissioning engineer will also sign the report. Kindly
hand over the commissioning report to the commissioning

Installation and operation 5.3

engineer. Please fill in also the warranty card that comes Checklist for engine running performance
along with the compressor and hand it over to the
engineer. The engineer will send the report and the card to 1 Check the engine lubrication oil pressure.
ELGi’s Service Department — Compressor Division, Head 2 Check whether the alternator is charging.
Office.
3 Check the hour meter and confirm that it is working.
ELGi ships the compressor unit without the compressor
Check whether the engine exhaust joint leakage is
suction duct assembly, engine suction assembly and 4
high.
engine exhaust duct assembly. These are packed
Check whether there is any leakage in the suction
separately and shipped along with the unit. During 5
line.
commissioning you need to fix them on the unit before
starting it. 6 Check the tightness of the air suction rubber elbow.

On receipt of the compressor unit at your warehouse, 7 Check whether the roof light condition is ok or not.
please open the door and take the compressor manual Check whether there is any leakage from the
8
bag, which is tied to the lifting bail pillar. In the flanges and joints.
compressor manual bag you will find the compressor
manual, engine manual, compressor warranty card, engine Compressor re-commissioning checklist
warranty card, battery manual & battery warranty card,
test certificate and packing slip. The compressor door keys 1 Check/clean air filter element.
and panel keys are tied to the service line ball valve Check/ensure that the clamps on the duct are
2
handle. tightened properly.

Checklist for engine preparation before Check/ensure that the Mounting Bolts of Airend &
3
engine are tightened properly.
commissioning
Check/ensure that the cooler mounting bolts are
4
Fill/check the oil level in the engine using the tightened properly
dipstick provided on the engine block. If required Check/ensure that the air-oil receiver mounting
1 add oil so that it reaches the necessary level. 5
bolts are tightened properly.
Consult with the local Deutz representative for the
right grade of oil. Check/ensure that the canopy bolts are tightened
6
properly.
Check/ensure that the coupling bolts are tightened
2
properly. 7 Check the condition of the main oil filter element.

Ensure that the battery is charged for 48 hours Pour new compressor oil into the air-oil receiver
3 8
before the compressor is commissioned. tank. The compressor oil fill capacity is 9 litres.

Check/ensure that the battery terminals are Check/ensure that the oil lubricating line on the
4 9
connected properly. airend is tightened properly.

5 Check the fan belt tension. Check/ensure that the pulse line to the blow down
10
valve is tightened properly.
Check/ensure that the clamps holding the exhaust
6 manifold on the silencer and bellows are tightened Check/ensure that the pulse line to the actuator is
11
properly. tightened properly.

7 Check the air filter condition and clamps tightness. Check/ensure that the pulse line to the pressure
12
regulator assembly is tightened properly.
Check/ensure that the engine bed mounting bolts
8 Check/ensure that the intake valve assembly is
are tightened properly. 13
fitted to the airend properly.
Check/ensure that the engine fan shroud bolts are
9 Check for any loose connections on the electrical
tightened properly. 14
terminals on the control panel board.
Check the gap between the engine fan and the
10 15 Check/ensure that the oil hose is fitted properly.
shroud and its position.
Check the engine belt tension and adjust its Check/ensure that all the bolts of the trolley, base
11 16
tightness. frame and wheels are tightened properly.

12 Check the condition of the engine belt. Check whether the towing arrangement and trolley
17
are fitted properly.
Check the engine tripping switches and their
13 Check/ensure that there is no damage to the
condition. 18
electrical cables to avoid a short circuit.
14 Check the condition of the engine and airend AVM.
19 Check the condition of the door hinges.

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

21 Check whether the air suction rubber elbow is tight.

Installation and operation 5.4

5.1.5 Pre-shipment procedure for
compressor stored for more than six
months
5.1.5.1 Coolant system
 Drain cooler.

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

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

5.1.5.2 Fuel system

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

 Fuel hose ends to be tightened or blocked to prevent

the moisture entering in to the system.

 Flush the system by air pressure of 10 psi.

 Block the opening in fuel system.

 Remove the fuel filter element.

5.1.5.3 Lube oil system

 Drain all the oil from the pan.

 Flush the oil system at a air pressure of 15 psi.

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

 Check the suitability of the oil before starting the

engine.

 Follow the specifications of the oil.

 Remove the used oil filter element including the bypass

and place a new unused element in it and despatch.

 Care is to be taken at the time of commissioning to

despatch the unit with a new filter element, and at the
time of commissioning the element refitted so that the
engine starts without any problem.

 This is applicable for fuel system filters also.

Installation and operation 5.5

 5.2 Preservation for long idle storage

If your compressor is going to remain unused for six

months or longer, special measures must be undertaken to
ensure the protection of the following components

 Airend

5.2.1 Airend
 To Remove the inlet valve on the suction of the airend.

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

 Rotate the input shaft 10 rounds clockwise/

anticlockwise direction.

 Remove the discharge plug after pouring rust-

preventive oil to drain the oil.

 After draining the rust-preventive oil from the airend,

refit the discharge plug.

 Close the suction by inlet valve.

 Continue this procedure every three months until

usage.

 Use CORTEC369 rust-preventive oil or any equivalent oil

available with you.

Figure 5.1. SINGLE-STAGE AIREND—AXIS MODEL (225)

Figure 5.2. TWO-STAGE AIREND—AXIS MODEL

(284-159)

Installation and operation 5.6

 5.3 Operating instructions

5.3.1 Pre starting checks  Fill the recommended compressor oil to the middle of
the oil sight glass on the receiver tank. The first-time
Every compressor is test run in the factory and carefully fill should be to the middle of the sight glass. Rest of
checked before shipment. The test run confirms that the the oil to be poured only after the initial start. Refer to
compressor conforms to the specifications and runs the Initial start instructions given in the following
perfectly. However, regardless of the checks carried out at pages.
the factory, the compressor could be damaged during
 Check and ensure that the oil filter is fitted properly.
transport. We recommend that the compressor be
examined for such damage and if any damage is found  Keep fully open the air outlet line ball valve (provided
that it be reported to the nearest dealer/Elgi Equipments on the front side of the compressor) before starting the
Ltd. compressor

 Check engine oil level by removing the dipstick

provided on the engine block.
Important functional components in the compressor (such
as the minimum pressure valve, pressure relief valve, inlet  Check oil in the fuel injection pump
valve, pressure switches and temperature switch) are
adjusted and fitted. Alterations to these components are  Use recommended coolant as per Engine manual.
not allowed without prior consultation with the  Check belt tension on engine fan drive. Refer engine
manufacturer.
manual for guidelines.

 Check diesel level in the diesel tank

The minimum pressure valve and pressure relief valve are  Ensure authorized electricians only carryout the
spring actuated. electrical work. Study electrical circuit diagram before
starting work.

 Ensure Electrical supply is disconnected and check all

If these instructions (WARNING, ATTENTION) are not
complied with, accidents can occur causing injury to screws on the electrical connections for tightness (carry
persons or damage to equipment out this check again after 50 operating hours)

Ensure battery connections as per wiring diagram

5.3.2 Starting the compressor
Operate the compressor with doors kept closed.

Points to be Observed Before Start

 The operator is expected to employ safe working

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

 The user of this compressor is responsible for its safe

operating conditions.

 Do not operate this compressor under heavy dust

conditions, toxic or inflammable gases could exist.

 Do not connect the compressor to a supply voltage

other than specification given in the technical
specifications section.

 Do not install the compressor in a place subject to

freezing temperatures. The air temperature conditions
at the air intake must be kept above +5°C.

 Ensure the hot air exhaust from the compressor is not

diverted through the louvers when installed inside
enclosed area. Hot air recirculation inside the enclosed
area will affect the compressor performance.

 Ensure adequate opening is made available for the flow

of atmospheric air when the compressor is kept in
enclosed area.

 Check the oil level in the receiver tank before starting

the compressor. The oil level should be up to the
middle of the oil sight glass provided on the receiver
tank.

Installation and operation 5.7

5.3.3. START - STOP procedure

Step 1 (START) :
 Close the outlet ball valve
(service line)
 Switch ON the power supply
to the compressor (Push the
isolator switch upwards)
 Rotate the loading valve to
STARTING MODE.

Step 2:
 Turn the over ride key to over
ride position for 5 seconds,
(till the engine speed reaches
above 250 rpm) & release it.
Then over ride key
automatically comes to start
position and compressor will
run in STARTING mode with
no air intake (for warming up
of Engine).

Step 3:
 Once the Engine gets warmed
up (after 20 sec) , rotate the
loading valve to LOADING
mode for compressor to
perform regular mode of
operation.

Step 4 (STOP) :
 Full open the outlet ball valve
(service line)
 Rotate the loading valve to
STARTING MODE
 Close the outlet ball valve
(service line)
 Wait till the tank pressure
reaches to MPV opening
pressure (4-4.5 bar)
 Turn off the override key
 Push the isolator switch
downward position (Switch off
condition)

Installation and operation 5.8

 6.0 Maintenance

Contents Page No.

6.1. Maintenance 6.2
6.1.1 Maintenance intervals 6.3

6.1.1.1 Maintenance Check List for Two Stage DPSAC portable Compressor (fitted 6.3
with Spin on filter elements)
6.1.2 Service information 6.5

6.1.3 Maintenance of individual components & systems 6.5

6.1.3.1 Oil filter – spin on type 6.5

6.1.3.2 Separator element 6.6

6.1.3.3 Air inlet filter 6.6

6.1.3.4 Drive coupling 6.7

6.1.3.5 Control system 6.8

6.1.3.6 Minimum pressure valve 6.8

6.1.3.7 Oil stop valve 6.9

6.1.3.8 Blow down valve 6.9

6.1.3.9 Discharge check valve 6.10

6.1.3.10 Pressure regulator valve 6.10

6.1.3.11 Single-acting actuator 6.11

6.1.3.12 Airend maintenance 6.12

6.1.3.13 Oil cooler and radiator maintenance 6.12

6.1.3.14 Battery maintenance 6.12

6.1.3.15 Flushing the compressor 6.12

6.2. Troubleshooting 6.13

6.3. Decommissioning, dismantling & putting out of service 6.16
6.3.1 Waste disposal 6.16

6.3.2 Dismantling the compressor 6.16

6.3.3 Decommissioning the compressor 6.16

6.3.4 Disposal of consumables and replaced parts 6.16

6.4. ELGi services 6.17

6.4.1 ELGi customer care system (ECCS) 6.17

6.4.2 ELGi genuine spare parts 6.17

6.4.3 Air audit 6.17

6.5. Appendix 6.19

6.5.1 Conversion tables 6.19

6.5.2 Torque values 6.20

6.5.3 Service log book 6.21

6.6. Disclaimers 6.23

Maintenance 6.1
 6.1 Maintenance

As you proceed in reading this chapter, it will be easy to

see that the maintenance program of the unit is quite
minimal but important. The use of the service indicator
provided for the suction filter alert you when service
maintenance is required.
For the maintenance requirements of engine, refer the
engine manual for a detailed description of service
instructions.
Daily Operation
Prior to starting the machine, it is necessary to check the
oil level in the receiver tank. Should the level be low, add
the necessary amount. If the addition of oil becomes too
frequent, a problem has developed which is causing this
excessive loss. See the troubleshooting section under
excessive coolant consumption for a probable cause and
remedy.
After a routine start has been made, observe the
instrument gauges and be sure they monitor the correct

NOTE
While using synthetic oil for compressor : Carryout the first
oil change after 100 hours of operation and subsequent oil
changes after every 2000 hours of operation.

Do not remove caps, plugs or other components when the

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

readings for that particular phase of operation. After the

machine has warmed up it is recommended that a general
check on the overall machine and instruments be made to
assure that the compressor is running properly.

Maintenance 6.2
6.1.1 Maintenance intervals

6.1.1.1 Maintenance check list for single stage DPSAC portable compressor (fitted with spin on filter elements)

Maintenance schedule for DPSAC - Water well and C&M

Periodic maintenance interval

Repeat
Month (Not applicable)
Sl. Maintenance s
Action Once
No Check points Dail
to be in 3
y
taken days
Repeat
250 500 750 1000 1500 3000 4500 6000
Hours

1 Oil level Check

Clog indicator, Air

2 Check
filter

Oil leakage / Air

3 Inspect
leakage

Battery electrolyte
4 Inspect
level
* Moisture from
Drain
5 separator receiver
moisture
tank
Air filter (Outer
6 # Clean
element only)
Inspect
* Oil cooler & Radiator
7 and
(External)
clean
Visual check of drive
8 Inspect
coupling element

« Compressor oil -
9 Replace
ELGi Airlube

« Main Oil filter - For

10 Replace
ELGi Airlube

** Return line oil filter

11 Replace
- For ELGi Airlube

Compressor oil - ELGi

12 Replace
Airlube plus

Main Oil filter - For

13 Replace
ELGi Airlube plus

** Return line oil filter

14 Replace
- For ELGi Airlube plus

15 * Air filter element set Replace

Air-oil separator
16 Replace
element

17 ARV kit Replace

18 Blowdown valve kit Replace

19 Pressure regulator kit Replace

20 Actuator kit Replace

Maintenance 6.3
 Maintenance schedule for DPSAC - Water well and C&M

Periodic maintenance interval

Repeat
Month (Not applicable)
Sl. Maintenance s
Action Once
No Check points Dai
to be in 3
ly
taken days
Repeat 25 75 150 300 450 600
500 1000
Hours 0 0 0 0 0 0«

21 Actuator assy Replace

Discharge check valve

22 Replace
kit and gasket

23 Oil stop valve kit Replace

Minimum pressure
24 Replace
valve kit
Discharge line &
25 Interstage pipe Replace
coupling element

26 Control line MOS filter Replace

Inlet rubber elbow -
27 Engine and Replace
compressor
28 Return line strainer Replace

Butterfly valve assy.

29 Replace
With gasket

30 Safety valve assy Replace

Anti-vibration mtg -
31 Engine, Compressor & Replace
ROC
Thermal valve
32 Replace
element
Temperature gauge
33 Replace
and pressure gauge
High discharge
34 Replace
temperature switch

35 Lubrication hose kit Replace

36 Return line strainer Clean EVERY OIL CHANGE

Check electrical wire
conditions and all
37 Inspect EVERY OIL CHANGE
engine/compressor
tripping switches
Recommendation for
38 REFER ENGINE MANUAL
engine consumables

* Cleaning/Replacement interval subject to environmental conditions & For first 500 hours oil filters and oil to be
applications replaced
Valve kits cleaning is recommended based on
** For two stage airend
site condition
# As per airfilter clog indicator, Clean outer air filter element as per
procedure. Cleaning of element is recommended 3 times after which Note - Actuator kit (20) and Actuator assembly
the element has to be replaced/1000 hours whicever is earlier (21) has to be replaced alternatively every
1500 hours as per schedule
 If applicable

Maintenance 6.4
6.1.2 Service information

BAIL LIFT
RADIATOR COOLANT COVER
FILL COVER

AIR
FILTER

AIR
FILTER

FUEL
CAP

Figure 6.1. Service information

a) Air filter  Take the separator element & gasket

 Open the door 6.1.3 Maintenance of individual

 Remove the wing nut available in the air filter and open components and systems
the cap Check all accessories independently to verify that they are
 Remove the air filter element. functioning as required and replace their components as
necessary. After maintenance restart the compressor
b) Radiator water fill as mentioned in section “Operating instructions”.
 Open the door on top of canopy near engine silencer 6.1.3.1 Oil filter – spin on type
 Open the cap on top of radiator to fill coolant Procedure
 After filling the coolant do remember to close cap & The lubrication and cooling system of the compressor is
door. provided with a spin on filter with an integral bypass valve.
c) Tank oil filling It is located between the (air-cooled or water–cooled) oil
cooler and the compressor unit. When a new element is
 Open the oil fill cap in the tank (Note: The Sump installed all the oil flows through the entire area of the
pressure must be zero) element, from outside to inside. As the element becomes
 Pour the oil using funnel until the oil reaches the centre contaminated with dirt, the pressure drop across the
of oil sight glass. element increases and the bypass valve opens. Thus the
flow of oil through the system continues and prevents any
 Do remember to close it again. damage from loss of oil. An exploded view of the oil filter
d) Air oil separator (AOS) element is provided in the accompanying figure. This is a full-flow
filter with a replaceable pleated element. For servicing this
 Remove the AOS Element service cover at top of canopy
filter, order the repair kit. The procedure for complete
 Remove the top plate on tank by loosening all bolts servicing of this filter is explained below.

Maintenance 6.5
Disassembly 6.1.3.2 Separator element
Loosen the filter elements and remove the same. The separator element must be changed after every 1500
Reassembly hours of running. Order the separator element kit. Follow
the procedure listed below for separator replacement.
Apply a thin film of oil to the gaskets on the new element.
Procedure
Tighten the new element on to the filter head, by hand
only.  Relieve the oil pressure from the receiver tank and all
Oil Service Procedure fluid lines.

 Drain the old oil from the sump/separator tank.  Disconnect all the piping connected to the receiver tank
cover to isolate the receiver tank from return lines, the
service line, etc.

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

 Lift the cover plate from the receiver tank.

 Remove the separator element.
 Inspect and clean the receiver tank for rust, dirt, etc.
 Place the new separator element in the receiver tank,
taking care not to dent it against the tank opening.

 Clean the bottom of the receiver tank and remove any

rust.

 Replace the cover plate and fasten the cover on the

receiver tank.

 Reconnect all piping. While doing so, make sure that

the return line tubes have a dimensional clearance of
¼"above the bottom of the separator element. This will
ensure that there is a proper oil return flow to the
compressor.

 Clean the return oil strainer before restarting the

machine

6.1.3.3 Air inlet filter

Figure 6.2 Oil filter When the air filter clog indicator indicates a blocked
condition, remove the air filter and replace it with a new
 Drain the old oil from the oil cooler inlet/outlet points. air filter. Refer to the accompanying figure for details of
the air inlet filter.
 Remove the oil filter elements (main oil filter/bearing oil
filter/return line filter).

 Rotate the coupling assembly by rotating the engine fan

and remove the oil completely from the separator tank.

 Replace the oil filter elements (main oil filter/bearing oil

filter/return line filter).

 Refit all the plugs of the sump, oil cooler and oil filters.
 Use oil (refer “Technical data”).
 Run the unit for a few minutes and stop the compressor
after closing the service ball valve.

 Recheck the oil level in the sump. It should be at the

half mark of the glass after the fumes settle down. If
necessary, add oil.
After 2000 hours of running, clean the receiver tank
thoroughly. Also check each of the accessories
independently to see if it functions and replace the Figure 6.3 Air inlet filter
components as necessary.

Maintenance 6.6
Never clean air filter with compressed air Aluminium casting to Coupling element
fly wheel locking bolts to hub
 Place a bright light inside the element to inspect it for No.
damage or leak holes. Light rays will pass through the Torque Torque
Grade 8.8 Grade 8.8
element where holes are present and destroy the same. (Nm) (Nm)

 Inspect all gaskets and gasket contact surfaces of the 01 3/8" 55 M12 90
housing. Should faulty gaskets be evident, correct the
condition immediately.

 If the clean element is to be stored for later use, it

Assembling
must be stored in a clean container.
 Check the engine crankshaft end play using a dial
 After the element has been installed, inspect and
gauge in the following manner. Remove the engine
tighten all air inlet connections prior to resuming
inspection door. Position the crankshaft at any end
operation if necessary.
using any lever and measure the run-out of the
6.1.3.4 Drive coupling crankshaft at the fan side using a dial gauge. Then
move the crankshaft to the other end using the lever
Dismantling
and measure the end play as well as the runout.
Whenever major repair/overhauling is carried out on the
unit, the airend should be removed. The following  Measure the depth of the mating face of the engine
dismantling and assembling procedure is to be followed. housing and engine flywheel.

 Unscrew the bolts on the engine flywheel.  Assemble the aluminium drive disc on the flywheel.
 Unscrew the bolts on the adaptor ring.  Assemble the adapter ring on the airend mounting face.
 Remove the airend bottom support screws.  Clean the hub bore and insert it on the compressor
shaft using a pusher.
 Lift the airend along with the drive coupling and place it
on the work table.  Assemble the rubber element with the hub.
 Unscrew the bolt connecting the rubber element to the  Now take the airend to the engine and couple them by
hub. clamping the adaptor ring with the engine flywheel.

 Using a puller remove the hub from the airend shaft. NOTE
 Clean all the components thoroughly. If any component  A drive coupling operating in a correctly assessed
is found damaged, replace it with a new one. system requires no maintenance. It is recommended
that the rubber blocks/rubber diaphragm be inspected
Use the following torque values for tightening the every 2500 hours.
screws
 A small amount of rubber dust is normal. Large
quantities of dust during initial running require
inspection. During assembly assemble all components of
the drive coupling with the proper torque values.

 Assemble all the components of the drive coupling with

the required torque.

Figure 6.4 Drive coupling

Maintenance 6.7
6.1.3.5 Control system Continue closing the service valve slowly. The speed of
the engine reduces while the butterfly valve closes to
The first step in adjustment of the control system is match the output. At this time the pressure regulator
adjusting the control linkage between the engine governor valve adjustment is complete.
and actuator. Adjust the slider in such a way that engine
reaches its full rated speed when the engine is started. At
the full rated speed of the engine the butterfly valve
should be fully open or approximately 15–20° off the
vertical.

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

Operating adjustment
Start the compressor. Allow the unit to operate until the
normal operating temperatures are attained. Ensure that
the service valve is fully open during this time. Adjust the
engine to operate at its full rated speed as per the
specification sheet.
Butterfly valve adjustment
IN
The butterfly valve opens and closes with respect to the OUT

condition of the service valve. The pressure regulator

valve actuates the actuators of both the butterfly valve Figure 6.6 Pressure regulator valve
and the engine governor according to the service pressure
requirement. Clean the butterfly valve after every 1500
hours of running. Remove and clean the centre flap
mating surface area.
Idle speed adjustment
RUBBER
CHROMET The last step in capacity control adjustment is adjustment
of the engine idle speed and compressor butterfly valve.
Continue closing the service valve. The speed of the
engine will drop with a constant working pressure and
closing of the butterfly valve to match the output of air.
When the engine reaches 1650 rpm, adjust the stop screw
at the engine governor, thus preventing a further drop in
the speed of the engine. Now close the service valve fully.
Once the engine is idling at the specified speed, the inlet
valve should be closed. Then the air pressure will stabilize
at 1 kg f/cm2 more than the set working pressure.
By changing the hole position in the governor lever, you
can set the idling speed suitably.

6.1.3.6 Minimum pressure valve

The details of the inner elements of the minimum pressure
Figure 6.5 Butterfly valve valve are shown in the accompanying figure.
Minimum pressure valve maintenance is quite minimal.
The only part which normally requires replacement is the
‘O’ ring on the piston.
Pressure regulator valve adjustment The minimum pressure valve cover is under heavy spring
tension. Loosen the cover bolts alternatively by one turn
Turn the pressure regulator valve screw clockwise to
each to relieve the spring tension.
ensure that it is out of adjustment. Start closing the
service valve slowly till the rated pressure is reached. The Before performing maintenance on the valve, be sure that
engine should operate at the rated speed with the the pressure has been fully relieved in the machine
compressor so that a condition is obtained where the
engine operates at the rated speed to the rated pressure
of the compressor. Turn the pressure regulator valve Extreme caution should be exercised when removing the
screw counter-clockwise till the actuator begins to cap or cover from the body because of the spring tension.
operate. Lock the adjusting screw with a lock nut.
Maintenance 6.8
 CYLINDER
HEX BOLT M6 X15

NYLOCK NUT M6

PISTON

O-RING

STEM

QUAD RING

VALVE BODY

Figure 6.7 Minimum pressure valve

receiver tank and that the downstream pressure has been POPPET
vented to the atmosphere.
To replace the ‘O’ ring, follow the procedure explained SPRING
below.

 Evenly remove the cap to relieve the spring tension. GASKET

 Remove the spring.

CAP
 Remove the piston.
 Remove the ‘O’ ring and discard it. Figure 6.8 Oil stop valve
 Clean the piston.
 Replace the ‘O’ ring.  Remove the valve seat from the stem by unscrewing it.
Replace it with a new one.
 Coat the piston and ‘O’ ring with grease.
 Remove and replace the gasket between the valve body
 Replace the piston. cap and the valve body. Use a new spring.

 Replace the spring and cap.  Reassemble the spring and cap.
6.1.3.7 Oil stop valve 6.1.3.8 Blow down valve
To use the repair kit, follow the instructions given below Blow down valve maintenance is limited to replacement of
for proper installation. the cover gasket and internal ring and seat.

 Remove the cap screw securing the cylinder to the Using the repair kit, follow the instructions given below for
proper installation.
valve body and remove the cylinder. Inspect for
scratches, scoring, etc.  Remove the four screws on the top cover which hold
 Disassemble the ‘O’ ring from the stem by removing the the assembly together.
nylock nut at the end of the stem.  Pull the top cover away from the body.
 Discard the ‘O’ ring and nylock nut. Replace these with  Remove the old gasket and replace it with the new one.
the new ones provided in the kit. When reassembling,
replace the ¼" nylock nut also.  Align the top cover with the body, replace the four
screws and tighten.
 Remove and replace the valve body ‘O’ ring.
Reassemble the cylinder and the valve body.  To replace the valve seat, loosen and remove the two
socket head screws in the bottom cover.
 Remove the valve body, cap and spring.
 Pull the bottom cover from the main body.

Maintenance 6.9
 CAP HEX. BOLT

RETAINER
OUT
T-RING
SPRING

RETAINER

PISTON
PLUNGER

STEM
HOUSING

DISC

SEAL WASHER

BODY

POPPET

SPRING

GASKET

Figure 6.10 Discharge check valve

TOP COVER

WASHER  Place the spring and plunger in position on the housing

HEX SCREW
as they were prior to disassembly.

 Replace the plug screws to secure the cover to the

Figure 6.9 Blow down valve housing and reconnect all the disconnected piping.

 Replace the flexible hose and start the machine to

 Remove the cover ring, spring, seat cup and seat. check for leaks.
Discard the seat and ring, and replace them with the 6.1.3.10 Pressure regulator valve
new ones in the kit.
Pressure regulator valve maintenance requires
 Reassemble the bottom cover. replacement of the diaphragm.

6.1.3.9 Discharge check valve Use only the repair kit. Follow the procedure given below
for proper installation.
To dismantle the discharge check valve, follow the
instructions given below.  Loosen the lock nut and turn the adjusting bolt counter-
clockwise until the inner spring tension is relieved. The
 Dismantle the flexible hose on the discharge piping adjusting screw should turn freely when the spring
between the airend and the receiver tank. tension is relieved.
 Dismantle the hose adapter and the reducing bush  Remove the top housing from the bottom housing to
fitted on the valve outlet port. allow access to the internal parts.
 Unscrew the valve housing from the compressor unit.  Next remove the spring button and the spring. Loosen
 The assembly should now fall away from the the pressure plate nut on the top seat to replace the
compressor unit. diaphragm. The replacement is available in the repair
kit.
 Remove the three Allen screws on the housing.
 Remove the plug on the housing and loosen the fourth
smaller Allen screw.

 The adapter can be separated from the housing.

 Check the spring and plunger for polishing or wear.

Maintenance 6.10
 SPRING SEAT TOP

HEX SCREW
SPRING

LOCK NUT

DAMPENER

PRESSURE PLATE NUT

COVER
LOCK WASHER

SPRING SEAT BOTTOM

SEAT RING DIAPHRAGM

DIAPHRAGM GASKET

BODY
SEATGASKET

Figure 6.11 Pressure regulator valve

6.1.3.11 Single-acting actuator  Remove the plunger along with the plunger rod.
The single-acting actuator requires a maintenance check
 Check the cup seal. Change it if it is found damaged.
every 6 months or 1500 hours of operation, whichever is
earlier.  Remove the spring and check the stiffness.
During this check, replacement of components is not
 Replace worn out/damaged components before
necessary if they are in a good condition. Thorough
assembling.
cleaning and lubricating of the moving components should
be sufficient. But once in a year all the sealing
components and the spring have to be replaced.
The procedure is given below.

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

SPRING

END COVER CYLINDER BODY

‘O’ RING
THREADED BUSH

BUSH LOCK NUT

PLUNGER ROD

PLUNGER

HEX BOLT—M8x30, SPRING WASHER—M8, HEX NUT—M8

CUP SEAL
Figure 6.12 Single-acting actuator

Maintenance 6.11
6.1.3.12 Airend maintenance
This needs special tools, jigs and fixtures for repair work. 6.1.3.15 Flushing the compressor
Please contact the ELGi dealer for any assistance with
A. For new compressors
airend maintenance.
 Drain the previous fluid from the sump, piping, filters
6.1.3.13 Oil cooler, radiator and charged
and fluid cooler, preferably while the fluid is hot.
air cooler (CAC) maintenance
 Drain the fluid filter elements.
The compressor unit needs to be shut down before any
maintenance work is done on the oil cooler and radiator.  Drain thoroughly.
Oil cooler/radiator/CAC : Remove the ROC canopy B. For dirty or varnished compressors.
cover, fan guard and clean it using an air jet with a
pressure less than 3 bar.  Drain the previous fluid from the compressor while the
fluid is still hot and change the fluid filter (s).
6.1.3.14 Battery maintenance
 Drain the dirty/solidified oil and fill the tank with Cabol
 Clean the battery and surrounding area with a wet cloth 68 (supplied by BPCL) cleaning fluid. Run the unit for
dipped in a diluted washing soda solution to remove the
24 hours with this oil and drain completely while it is
acid on the top. While doing so ensure that the vent
hot.
plugs are screwed on tight.
 After draining the cleaning fluid, fill with fresh oil.
 Clean the battery terminals in case they are corroded. Check the condition of the oil filter and separator every
 Apply petroleum jelly or Vaseline on the battery 250 hours.
terminals and fixing clamps.  After 2 hours drain the cleaner completely and change
 If the level is low, top up with distilled water/DM water filter (s) if necessary.
only (up to the maximum level).  Fill the compressor with compressor cleaner and allow it
 Check specific gravity of each cell at least once every to run for 48 to 72 hours. Monitor the filter (s) and
30 days in a vehicle, and if the gravity is less than change if necessary.
1.19, put the battery on bench charge after topping up  Run the compressor for 1 hour, drain completely and
to the maximum level.
change filter (s) if necessary.
 When installing batteries in series (two-battery systems  Drain thoroughly.
-12V), ensure that both the batteries have the same
specific gravity.  Submit a fluid sample for analysis after 200 hours run
time.
 The electrolyte in the battery should be maintained up
to the upper level only. NOTE
 Always keep the battery surface dry and dust-free.  During clean-up, watch for differential pressure in the
separator. When the sump pressure becomes 10 lb
 Check for the following voltage setting: greater than the line pressure, change the separator.

 Open circuit voltage: 12.5 V per 12 V battery  The above procedure is for a machine that is not too
badly varnished.
 On top of charge voltage: 15.9 to 16.5 V per 12 V
battery

 On H.R.D. for 15 seconds: 10.5 V per 12 V battery

 Vehicle charging voltage: 13.5 to 14.2 V per 12 V
battery.

 Ensure that the batteries are checked every month as

per the checklist.

 Ensure that charger/charging clips/other tools are clean

and in order/ charging clips tight & free from corrosion.

 Ensure that batteries are removed and kept away from

welding area in case of vehicle maintenance.

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

Maintenance 6.12
 6.2 Troubleshooting

This guide lists the most likely indications with possible causes. For any problem, follow the diagnosis in sequential order as
mentioned in the following charts. Before doing any work in the compressor, be sure that electrical supply has been cut off
and the entire compressor is depressurized.

Problem Cause Solution (go sequentially)

No fuel. Check fuel level and add fuel if necessary.

Clogged fuel filter. Replace the element.

Check electrolyte level and add water and recharge if

Low battery voltage.
necessary.

The electrical connections for the

following are to be checked

1. Check engine water temp switch

2. Check engine oil temp switch

3. Check engine oil pressure switch

4. Check compressor low pressure In any one of the switch the electrical connections (power
switch supply to be checked) and if the power is not coming to the
switch please rectify / replace it and ensure that the green
5. Check compressor high pressure light in the control panel is ON at the time of starting.
switch

6. Check compressor high temperature

switch
Engine not starting 7. Check engine solenoid switch

8. Check loose connection in control

panel wires.

Loose battery cables. Tighten cables.

Dirty battery cables. Clean thoroughly.

Clogged air filter. Clean or replace the element.

Engine problems may have developed. Refer to your engine manufacturer

1. Checks the NRV fitted before the moisture filter and if

necessary replace it.

2. Airlock in diesel hose line to be removed

3. Air Lock in fuel filter

Fuel not reaching the pump.
4. O ring not seated properly in fuel filter

5. No fuel in the fuel filter

Diesel tank id fitted very below the engine.

Engine starts and

Blown fuse. Check electrical continuity and replace if necessary.
stops immediately

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

Maintenance 6.13
 Problem Cause Solution (go sequentially)

No fuel. Check fuel level and add fuel if necessary.

Compressor discharge temperature

switch is open.

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

b) Low oil level in receiver tank. Add oil.

Check the colour of oil (minerals in case) and it should be

c) Dirty oil yellowish only. If the colour changed please change oil with
filters.

Machine shuts d) Clogged oil filter Change oil filter elements.

down with air
demand present Check for a short or open circuit to the fuel solenoid should
Defective discharge temperature switch this check out normal, it would be possible that the
temperature switch itself is defective.

Engine water temperature switch is

open.

a) Cooling air flow restricted. Clean the radiator core.

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

c) Defective switch. Replace.

b) Low water level. Fill the radiator with adequate water.

Air demand too great. Check service lines for leaks or open valves.

Check the filter indicator and change or clean element if

Dirty air filter.
required.
Line pressure not
Pressure regulator valve out of Adjust pressure regulator valve according to control
building
adjustment. adjustment instruction in the maintenance section.

Defective pressure regulator. Check diaphragms and replace if necessary.

Defective minimum pressure valve. Check and ensure piston is moving freely.

Pressure regulating valve is set too

Re-adjust.
high.

Leak in the control system causing loss

Check control lines.
of pressure signal.

Defective diaphragm in the actuator.

Improper Replace diaphragms.
(kit available)
unloading with an
excessive pressure
Defective pressure regulator valve. (kit
builds up causing Repair the valve.
available)
pressure relief
valve to open.
Inlet valve jammed. Repair / replace the valve.

Check all control lines and components and remove the

Restriction in the control systems
foreign particles clogging the system.

Jammed control linkage. Clogged air/oil Free the jammed portion of the linkage and adjust if
seperator element. necessary. Replace seperator element.

Clogged air filter. Clean or replace the element.

Replace seperator element and also change the compressor

Clogged air / oil seperator.
Insufficient air oil and oil filter at this time.
delivery
Faulty pressure regulator. Adjust or repair.

Engine speed too low. Re-adjust engine speed.

Maintenance 6.14
 Problem Cause Solution (go sequentially)

Clogged return line. Clean oil return strainer and orifice.

It should be more than dew point temperature. Please refer

Check DOT of the unit.
the chart enclosed in last page of the manual.

Defective blow down valve. Replace kit.

It should be 1/2 liter. If it is more than half liter rain of

Check moisture level in the sump after
water from sump. Then replace the higher rated thermal
shut down the unit
valve.
Excessive
compressor oil Leak in the lubrication system Check all pipe connections and components.
consumption (oil
carry over through Return line orifice may be chocked and needs to be
service line) Return line orifice chocked.
cleaned.

Seperator element damaged or not

Change seperator element.
functioning properly.

Check the orifice and it should be fitted at outlet of return

Orifice fitted in wrong position.
line sight glass.

Excessive oil in the receiver tank. Drain to correct level.

Vertical shell bottom welding condition. Check welding condition.

Loose or broken fan belt. Tighten or change belt.

Dirty oil cooler core. Clean core thoroughly.

Clogged oil cooler tubes (internally &

Clean tubes thoroughly.
externally)

Low receiver tank oil level. Fill up to max. level.

Compressor over Clog oil filter. Clean or change the main oil filter and bearing oil filter.
heating
Check the pressure with a gauge (provision is given for
Inter stage pressure (first stage outlet) gauge fitment in first stage outlet cover) and it should be
is high. 3.5 bar max. If the pressure is more please contact ELGI
for rectification.

Clogged oil return line. Clean oil return strainer and orifice.

Drain and flush the system thoroughly. Use recommended

Wrong grade of oil.
grade of oil.

Loose or broken fan belt. Tighten or change belt.

Dirty radiator core. Clean core thoroughly.

Engine over Faulty engine thermostats. Replace thermostats.

heating and
tripping Clogged radiator. Clean thoroughly.

Low oil level. Refill.

Other engine problems. Refer to engine manual.

Back flow of oil

through suction Check oil stop valve, service if necessary. Check discharge
Faulty oil stop valve / DCV
when unit is check valve
stopped

Oil throw through

BDV during shut Faulty Blow down Valve Inspect, rectify or replace the kit.
down

Moisture
condensation in
Faulty Blow down Valve Inspect, rectify or replace the kit.
receiver tank (air
oil seperator sump)

Maintenance 6.15
 6.3 Decommissioning, dismantling and
putting out of service

If you do not intend to use the compressor or any of its accordance with the pollution control norms prevailing
parts, you must dismantle and putting out of service. at the time of compressor installation or use.
These tasks must be carried out in compliance with the  Parts of the compressor that are replaced have metal
standards in force of that particular country. and rubber components. These may be recycled and
6.3.1 Waste disposal disposed off according to pollution control regulations,
respectively.
 Use of compressor generates waste. The residues from
agricultural, industrial, crafts, commercial and service  Rubber items such as AVMs, coupling elements, and O-
activities must be treated as waste, which needs to be rings should be disposed and replaced before running
disposed off properly. Deteriorated or obsolete again.
machines are also classified as waste.
 Special attention must be given to active carbon filters NOTE
as they cannot be included in urban waste. Observe the ELGi is not responsible for the disposal of old oil or
waste disposal laws in force where the compressor is condensate. It is the responsibility of customer to dispose
of the foregoing in accordance with local environmental
used.
statutory laws.
 It is mandatory to record loading or unloading of
exhausted oils, obsolete machines and toxic harmful
wastes that derive from heavy or light industry
processes. The compressor does not give any warnings during short
operating times. If it is operated below the dew point and
 It is especially important that exhausted oils be moisture condensate may mix with oil. This will reduce the
disposed off in compliance with the laws in the countries lubricating quality of the oil and lead to damage of
compressor.
of use.

6.3.2 Dismantling the compressor

 Dismantle the compressor in accordance with all the
precautions imposed by the laws in force in the country
of use.
 Before dismantling, request an inspection by the
relevant authorities. Disconnect the compressor from
the electrical system.
 Eliminate any interfaces the compressor may have with
other machines, making sure that interfaces between
remaining machines are unaffected.
 Empty the air oil tank containing the lubricating oil and
store in compliance with the laws in force.
 Proceed with the disassembly of the individual
compressor components and group them together
according to the materials they are made of: Steel,
Stainless Steel, Aluminium and plastic parts.
 Then scrap the machine in compliance with the laws in
force of the country of use.

6.3.3 Decommissioning the compressor

 Drain the oil from the cooler and air oil tank. Dispose of
it properly.
 Make sure all the compressed air is vented out through
ball valves and safety devices residing in the
compressor.
 Ensure that all the external supply lines have been
properly disconnected from the compressor before
decommissioning.

6.3.4 Disposal of consumables and

replaced parts
 The moisture condensate separated from the
compressed air contains oil particles. Disposal of
condensate and filter element is to be done in

Maintenance 6.16
 6.4 ELGi Services

6.4.1 ELGi customer care system (ELGi  Northern Region: Rajasthan, Uttar Pradesh, Delhi,
Haryana, Punjab, Uttaranchal, Himachal and Jammu &
CCS)
Kashmir.
ELGi provides dedicated customer care and after-sales
Contact Numbers: You can contact CCS also with the
support through the ELGi customer care system (CCS), a
following numbers:
computerized system developed in-house. The CCS aims
to minimize the time taken to resolve customer Telephone: 0422-2589206 / 241 / 242 / 243/ 244 / 245 /
complaints. 97900 21100

Service requests/complaints Fax: 0422-2589240

The CCS toll-free telephone number 1800-425-3544 Please send the following details to the mail, thus enable
(accessible within India through BSNL and MTNL lines) us to take immediate action.
takes the customer’s call to our centralized customer care 1. Name of the customer
center in Coimbatore. Customers can register their service
2. Compressor model
requirements or complaints here.
3. Fab. number
A unique tracking number is generated for each call logged
by the CCS. The customer receives an automatic e-mail 4. Contact person name
acknowledgement with the tracking number and details of 5. Phone number
the call for reference.
6. Nature of complaint
A service engineer is assigned to the call, and the date and
time of the engineer’s visit are communicated to the 7. Hour meter reading
customer by e-mail. Every requirement or complaint must You may use the CCS by sending e-mail to: [email protected]
be resolved and closed in the CCS within a specified time
Customer satisfaction survey
limit, failing which the complaint is automatically brought
to the notice of the manager. If the issue remains If you have used the CCS, you may be contacted for your
unresolved, it will get escalated to the managing director. feedback on our after-sales support. Your response helps
The CCS ensures that not only the customer complaints ELGi to improve its service.
are logged but they are also attended to on time, every International customers:
time.
Refer contact information at the end of this manual book.
Enquires
6.4.2 ELGi genuine spare parts
A number of calls received by the CCS relate to customer
queries regarding products and spare parts. The details When ordering spare parts, refer to the lists provided in
are noted, and basic information on product specifications the parts manual and identify the part number. Specify the
and usage are provided. The caller is then referred to a part number and quantity, in addition to the name plate
salesperson at the head office or the appropriate branch details. Global support center of ELGi ensures the supply
for follow-up. of the quality spares on time. Ensure that you are using
the genuine spare parts so that your Compressor will be
The CCS database
working efficiently and effectively. Refer to section 6.1.3
The CCS also creates a database of customers, adding for details on need of using genuine spares.
details of every new customer who calls, thereby building
Please contact our After sales team for any compressor
a large pool of installation details. These details are used
accessory requirements like VFD, Air-Dryer, etc.
to provide value-added services to improve customer
satisfaction with ELGi products. 6.4.3 Air audit
CCS-working hours We extend our proven capabilities in energy efficiency
The ELGi CCS works for six days a week from 08:30 to initiatives by carrying out air audits for our customers.
21:30 IST (Monday to Saturday). ELGi conducts audits and trains end users in key energy
Multi-lingual capability oriented functional areas. The audit reports prepared by
ELGi experts’ team include recommendations on short,
The coordinators at the CCS are multi-lingual. They can medium and long term measures for energy conservation,
handle calls in English and all the major regional along with financial estimates and analysis for
languages of India. implementation.
Coverage: The CCS toll-free number 1800-425-3544 is This air audit objective is to provide the customer:
accessible from the following areas:
 The framework for systematic collection of data relevant
 Southern Region: Tamil Nadu, Karnataka, Kerala, to the efficient operation of compressed air systems.
Puducherry, Andhra Pradesh, Telangana, Andaman &
Nicobar Islands.  A thorough analysis about the performance of the
compressed air system, identifying potential electricity
 Western Region: Maharashtra, Gujarat, Madhya savings and to provide sound recommendations for
Pradesh, Goa, Lakshadweep Islands. implementation of energy efficiency initiatives.
 Eastern Region: Orissa, Chhattisgarh, Jharkhand, Data analysis will be comprised of the information about
West Bengal, Bihar and the North-Eastern states. different areas such as air leakages, inappropriate use of
compressed air, compressed air system network,

Maintenance 6.17
compressed air system supply including compressor
internal maintenance conditions and even more.
The final report issued to the customer end will serve
the purpose of assisting concise, consistent and complete
presentation of the analysis, findings and recommendations
arising from a compressed air system audit.
Depending on the measurement, reporting and cost
requirements from the customer end, the intensity in level
of audit (base level or investment level) will be decided.
Also post implementation monitoring after air audit will be
provided if requested from the customer end.
For further information on air audit contact ELGi.
E-Mail: [email protected]

Maintenance 6.18
 6.5 Appendix

6.5.1 Conversion tables

Description From To Multiply by

Inches Millimetres 25.4

Metres Inches 39.37

Feet Millimetres 304.8

Length (L)
Metres Feet 3.281

Inches Thou 1000

Millimetres Micrometres 1000

Square metres Square feet 10.765

Area (A) Square feet Square inches 144

Square inches Square millimetres 645.16

Cubic metres Cubic feet 35.315

Cubic feet Cubic inches 1728

Cubic metres Litres 1000

Volume (V)
Cubic feet Litres 28.32

US gallons (liq) Litres 3.785

Imperial gallons (liq) Litres 4.546

3
Cubic feet per minute (cfm) Cubic metres per hour (m /h) 1.6988

Cubic feet per minute (cfm) lpm 28.32

Volumetric flow (Q)
Cubic metres per hour (m3/h) lpm 16.667
3
Cubic metres per minute (m /min) lps 16.667

Kilograms Pounds 2.205

Kilograms Grams 1000

Mass (M)
Kilograms Ounces 35.27
2
kg f/cm g psi g 14.223

psi g Pascal 6895

Pressure (P) bar g kg f/cm2 g 1.0197

bar g psi g 14.503

psi g kg f/cm2 g 0.0703

Degree Celsius (°C) Degree Fahrenheit (°F) °F = 9(°C)/5 +32

Temperature (T) Degree Celsius (°C) Kelvin (K) K = °C + 273.15

Degree Fahrenheit (°F) Degree Rankine (°R) °R = °F + 460

ft-lb f Joules 1.35582

ft-lb f Btu 0.001285

Heat (q), Work (W),
Joules Calories 0.2388
Energy (E)
Btu/h Calories/h 252

Kilowatts Btu/h 3411

Metric horsepower Kilowatts 0.7355

Power (P)
Imperial horsepower Kilowatts 0.7457

Table 6.1: Conversion table

Maintenance 6.19
6.5.2 Torque values
The tightening torque values for bolts and screws used in ELGi Compressors are provided in this section for reference. The
tolerance for the torque values is (-) 10% from the given value.

Thread size* Tightening torque (N-m) Tightening torque (lb-ft)

M4 2.9 2.13

M5 5.7 4.20

M6 9.8 7.22

M8 24 17.7

M10 47 34.66

M12 81 59.73

M16 197 145.28

M20 385 283.93

Table 6.2: Metric hexagonal head bolts and screws

Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)

¼" 45 33.19

½" 85 62.69

¾" 170 125.38

1" 330 243.39

1¼" 430 317.15

1½" 510 376.15

Table 6.3: BSP threads

Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)

9/16" 149 109.8875

7/8" 579 427.0125

Table 6.4: UNF threads

* Property class of 8.8 only

Maintenance 6.20
 Total Moisture Trip
Oil level Pre
operated Line System Discharge removal Cooler record Operator
Date From Till in AOS Filter Comments
hours / pressure pressure temperature from AOS cleaning descrip- sign
tank Cleaning
day tank tion

Maintenance
Low/
Start/Stop normal/ Before
Time high/ starting
change
6.5.3 Service log book – record of maintenance

6.21
 Total Moisture Trip
Oil level Pre
operated Line System Discharge removal Cooler record Operator
Date From Till in AOS Filter Comments
hours / pressure pressure temperature from AOS cleaning descrip- sign
tank Cleaning
day tank tion

Maintenance
Low/
Start/Stop normal/ Before
Time high/ starting
change

6.22
 6.6 Disclaimers

Please read this document and the warranty terms accompanying the product carefully before using our product.
By purchasing our product, you agree that you will assume total responsibility and risk for your use of the product.
The warranty terms of the product have been provided separately.
1. ELGi is not liable for failure of the compressor ( hereinafter “compressor” or “product”) to perform its obligations if such
failure is as a result of Acts of God (including but not limited to fire, flood, earthquake, storm, hurricane or other natural
disaster), war, invasion, act of foreign enemies, hostilities (regardless of whether war is declared), civil war, rebellion,
revolution, insurrection, military or usurped power or confiscation, terrorist activities, nationalization, government
sanction, blockage, embargo, labour dispute, strike, lockout or interruption or failure of electricity or telephone service
and any other reasons beyond ELGi’s control.
2. ELGi does not take responsibility for any damage or injury resulting from neglecting the safety instructions, warnings,
cautions, precautions, or non-observance of the normal caution and care required for installation, operation, maintenance
and repair of the product, even if not expressly stated, and such instances are specifically disclaimed by ELGi.
3. The entire literature including product description or any other information in this manual exclusively belongs to ELGi and
is subject to copyright. No person has any right to copy, modify, distribute, transmit, display, perform, reproduce, publish,
license, create derivative works, transfer or sell any information, or deal with the same in any other manner, without the
knowledge and written concurrence of ELGi, violation of which would amount to infringement of rights of ELGi and would
necessitate legal action.
4. The information published in this manual may include inaccuracies, or typographical errors. Changes may be periodically
added to the information herein. Any changes/improvements may also be made to the products stated in this manual and
ELGi is not liable if the readers are not updated with information.
5. Likewise ELGi is responsible only till the point of first sale to the ultimate customer and not thereafter and only if the
product is purchased from authorized dealers of ELGi. ELGi disowns liability on account of purchase of any second hand
product or purchase otherwise from unauthorized dealers. ELGi shall not be liable for any indirect, incidental, punitive,
special or consequential losses or damages including any loss of profit, loss of production, loss of income or contract, loss
of goodwill, expected savings or business relationships, arising out of or in any way connected with the usage of the
product or information in this manual.
6. In no event ELGi shall be liable for any claims or loss having a value higher than the original purchase price of the product
sold by ELGi or its network of authorised dealers.
7. These Disclaimers and the contents of this manual shall be subject to the laws of India and any disputes pertaining to this
manual or anything stated therein or any product stated therein is subject to the exclusive jurisdiction of the courts in
Coimbatore, Tamil Nadu, India.
8. No liability in connection with the product will accrue to ELGi,
 If any welding or related operation involving heat is carried out in the compressor. Never weld or modify any parts
including pressure vessels.
 If any damages to the product directly or indirectly arise due to long storage (6 months) of product and subsequent
corrosion of internal parts and which leads to fire or malfunctioning of the product.
 If the compressor package and its accessories are installed in such a way to allow moisture, rain, freezing temperature or
sun damage to affect the safe operation of the unit.
 If the person who operates / maintains the compressor does not adhere to all work related safety practices and regulatory
requirements.
 If unauthorized personnel other than ELGi authorized or trained personnel carries out commissioning, installation,
operation, maintenance and any repair work on the compressor.
 If the compressor and the compressed air are used for unintended use or are misused.
 If the compressor is operated below or in excess of its pressure and temperature limits.
 If the compressor “ON/ OFF” switch is operated through remote control situated away from the compressor location
without giving any adequate notice / alarm before starting the product .
© Copyright ELGi Equipments Limited, India 2018. All Rights Reserved.

Maintenance 6.23
PARTS MANUAL

DIESEL POWERED SCREW AIR COMPRESSOR

7.0 Air inlet system
[ Ref : 035303171 -X031356] PG 400-175 AC

Parts Manual 7.2

7.0 Air inlet system
[ Ref : 035303171 -X031356]

Sl.
Description Qty. Part Number
No.

1 AIREND 1 -

2 O RING 183.74 X 3.53 1 015403271

3 SPACER RING 1 035300059

4 O-RING ID117.1 X 3.5 2 015403276

5 BUTTERFLY VALVE - 4" 1 220210470

6 DUCT AIRFILTER TO AIREND 1 035302659

7 HOSE FILTER TO DUCT 1 B010306260001

8 SS T BOLT CLAMP DIA 159 1 B013704300002

SS T BOLT CLAMP DIA157-

9 1 B005004300012
DIA165

10 AIR FILTER ASSY 1 B474606

11 Spring Washer-M16 4 000996116

12 Hex Bolt M16X40 4 000906214

13 WASHER SPRING REC SEC M12 4 000996112

14 BOLT HEX M12X60 4 000906189

15 Spring Washer-M8 4 000996108

16 Hex Bolt M8x25 4 000906116

17 Plain Washer-M8 6 000996008

18 CROMET DIA 20 1 035400295

19 HEX BOLT M8 x 50 2 000906121

Parts Manual 7.3

8.0 Drive system
[ Ref : 035303014 - X031317] PG 400S - 175

Parts Manual 8.1

8.0 Drive system
[ Ref : 035303014 - X031317]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 ENGINE 6BTA 1 B009500890001 41 NA NA NA

2 DRIVE COUPLING S-2800, 1 B005400900006 42 ELBOW; TMS; 3/8"X3/8"NPT 1 22047681D

3 AVM ENGINE AIR END 4 B001401100002 43 ELBOW; TMS; 3/8"X3/8"NPT 1 22047681D

4 ADAPTER RING - SAE 3 1 030346470 44 GASKET 1 030447320

5 AXIS - 159 1 X019363 45 FUEL TANK 1 035302658

6 BRACKET AIR END SUPPORT 1 035400077 46 FUEL LEVEL PROBE 1 038400029

7 Bracket engine mtg RH 1 035400074 47 FILTER NIPPLE TRC 2000 1 000470340

8 Bracket engine mtg LH 1 035400075 48 PLUG : HEX ; 3/4" NPT 1 22037905E

9 Engine rear support 2 035400076 49 PIPE DIESEL TANK 1 035400572

10 RUBBER PAD 2 035400086 50 BRACKET ENGINE AIR FILTER - CUMMINS SCOPE

11 ENGINE EXHAUST SILENCER 1 ENGINE SCOPE 51 DUCT AIR TRANSFER TUBE - CUMMINS SCOPE

12 DUCT SILENCER OUTLET 1 035400573 52 40 DEG FAN AC 32" 1 B008103690002

13 DUCT - BELLOW TO SILENCER 1 035301648

14 SPRING WASHER M10 40 000996110

15 SPRING WASHER M12 18 000996112

16 SPRING WASHER M16 4 000996116

17 SPRING WASHER M8 11 000996108

18 SPRING WASHER M5 1 000996105

19 SPRING WASHER M6 1 000996106

20 Hex Bolt M10x25 20 000906144

21 Hex Bolt M12x30 14 000906183

22 Hex Bolt M16x50 2 000906216

23 Hex Bolt M10x30 16 000906145

24 Hex Bolt M16x25 2 000906211

25 Hex Bolt M10x35 4 000906146

26 Hex Bolt M8x30 2 000906117

27 Hex Bolt M8x25 9 000906116

28 Hex Bolt M5x16 1 000906054

29 Hex Bolt M6x16 1 000906084

30 Plain Washer-M12 12 000996012

31 Plain Washer-M16 4 000996016

32 Plain Washer-M10 12 000996010

33 Plain Washer-M8 13 000996008

34 Hex Nut-M12 4 000948012

35 Hex Nut-M10 8 000948010

36 Hex Nut-M8 6 000948008

37 WASHER SPRING RCS 3/8" 8 000996203

38 BOLT HEX 3/8"UNCX2 1/2" 8 000907232

39 Punched Washer-M10 8 000996059

40 BRACKET SILENCER MTG. 2 030447550

Parts Manual 8.2

9.0 Discharge system
[ Ref : 035303099 - X031343] PG 400S-175, PG 400-175

Parts Manual 9.1

9.0 Discharge system
[ Ref : 035303099 - X031343]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 BOLT HEX M8X25 2 000906116 40 FLANGE ASSY COOLER TO MOS 1 015305980

2 BOLT HEX M10X35 4 000906146 41 O-RING ID47.2X3.5 3 015400891

MANIFOLD AIOUTLET - 400/175

3 BOLT HEX M12X30 2 000906183 42 1 035303104
AC

HOSE ADAP.90DEG1/4"
4 BOLT HEX M12X35 8 000906184 43 2 B010506360046
NPTx1/4" BSP

5 BOLT HEX M12X40 8 000906185 44 COUPLING; TMS; 1/4"x1/4"NPT 1 22047683A

6 BOLT HEX M16X120 6 000906227 45 AIR OIL SEPARATOR TANK 1 035302127

7 2" BSP BONDED SEAL WASHER 2 000959399 46 1 1/2” BONDED SEAL WASHER 1 000959391

8 WASHER PLAIN M8 2 000996008

9 WASHER PLAIN M10 4 000996010

10 WASHER PLAIN M12 2 000996012

11 WASHER SPRING M8 2 000996108

12 WASHER SPRING M10 4 000996110

13 WASHER SPRING M12 20 000996112

14 WASHER SPRING M16 6 000996116

15 ELEMENT SEPERATOR 400 CFM 1 010452250

16 FLANGE ASSY - TANK TO MPV 2 015306799

17 O - RING ID60.0 X3.0 1 030449650

18 FLANGE DCV 1 035300363

19 O RING ID69.4X3.5 1 035400116

20 O RING ID56.7X3.5 2 035400187

21 GASKET 2 035400362

VALVE ASSY, DIS CHECK, 2S,

22 1 220311530
73N

23 NIPPLE; HEX; 3/4"NPT 1 22037903D

24 PLUG;HEX;1/4" NPT 1 22037905B

25 PLUG HEX 1” BSP 1 015402651

26 VALVE; GATE; 3/4"NPT 1 22041354A

27 SCR SOC HD M12X25 4 000983142

28 SIGHT GLASS OIL LEVEL 11/2" 1 A010018

29 ADAPTER DCV 1 035300362

30 BOLT HEX M12X45 2 000906186

31 SCR SOC HD M8X30 4 000983085

MINIMUM PRESSURE VALVE 2

32 1 035302649
INCHB

33 PLUG; HEX; 1/8"NPT 1 22037905A

34 PLUG;HEX;3/4"NPT 1 22037905E

35 BALL VALVE 3/4" 4 B312702

36 BALL VALVE 1 1/2" NPT 1 B312704

37 WATER SEPARATOR MS365 1 A010052

VALVE, PR RELIEF 1INCH 15

38 1 B012805340055
BAR

39 CONNECTOR-MOS OUT 1 015305936

Parts Manual 9.2

10.0 Cooling system
[ Ref : 035303100 - X031344] PG 400-175AC

Parts Manual 10.1

10.0 Cooling system
[ Ref : 035303100 - X031344]

Sl.
Description Qty. Part Number
No.

1 RADIATOR ASSY 1 B010901220002

2 ANTI VIBRATION MOUNT 4 B001401100003

3 MTG;ANTI VIB PS3/HDS-CM1 2 22037506A

4 ROC FRAME RH 1 035300343

HOSE - RADIATOR MAKEUP

5 1 035400126
LINE

6 WASHER,PLAIN M8 25 000996008

7 WASHER SPRING M8 36 000996108

8 FAN GUARD 1 030348410

9 WASHER PLAIN M12 20 000996012

10 NUT HEX M8 8 ZBP 12 000948008

11 BOLT HEX M12X30 20 000906183

12 BOLT HEX M8X25 36 000906116

13 BOLT HEX M10X25 4 000906144

14 WASHER SPRING REC SEC M12 38 000996112

15 OIL COOLER 400-175 AC 1 B011901090001

16 400-175 AFTER COOLER 1 B011301090001

17 ROC LH 400-175 1 035300937

18 TOP COVER-ROC 1 035300938

19 BOTTOM COVER-ROC 1 035300939

20 SHROUD - 400 AC 1 035300940

21 BOLT HEX M8X10 8 000906110

22 WASHER,SPRING REC SEC M8 8 000996108

23 BOLT HEX M12X25 16 000906182

24 BOLT HEX M12X35 2 000906184

BUSH, REDUCING 1/8 BSPX1/4

25 1 035400613
NPT

26 1/8 BSP BONDED SEAL 1 000959381

27 40 DEG FAN 400 AC 32" 1 B008103690002

28 SUPPORT SHROUD 2 035301517

29 PLUG HEX 5/8" UNF 2 010456320

30 NIPPLE;HEX; 1/4" NPT 1 22037903A

31 PLUG;HEX; 1/4" NPT 3 22037905B

32 PLUG;HEX; 1/2" NPT 2 22037905D

Parts Manual 10.2

11.0 Lubrication system
[ Ref : 035303101 - X031345] PG 400-175 AC, PG 400S - 175 6BTA

Parts Manual 11.1

11.0 Lubrication system
[ Ref : 035303101 - X031345]

Sl.
Description Qty. Part Number
No.

1 BOLT HEX M12X30 4 000906183

2 BOLT HEX M12X35 6 000906184

3 WASHER PLAIN M12 2 000996012

4 WASHER SPRING REC SEC M12 10 000996112

VALVE ASSY,OSV FLG TYP 1 1

5 1 035301016
2IN

6 AIREND INLET ORIFICE 1 035301034

HSG THERM VALVE 1 1/4" NPT

7 1 22031079A
M/C

8 ELBOW; PIPE; 90'; 1 1/4"NPT 1 22047677F

ELEMENT THERMAL VALVE 155

9 1 220322920
DEG

HOSE ADAPTER,ELBOW 1"

10 2 B96XX02
BSPX1"NPT

11 BOLT HEX M8X25 4 000906116

12 WASHER,PLAIN M8 4 000996008

13 WASHER,SPRING REC SEC M8 4 000996108

14 ADAPTER;HOSE;1"BSPX1"NPT 2 030446820

`HEX;REDUCING;NIPPLE;1-
15 1 220377330
1/4"X1"M

BUSH;REDU;ADAP;1 1/4"X1"
16 2 22037897T
NPT

17 NIPPLE; HEX; 1 1/4"NPT 1 22037903F

18 TEE;PIPE; 1" NPT 1 22047680E

19 FILTER HEAD - 150LPM 1 015300389

20 O-RING ID37.7X3.5 1 015402283

21 NIPPLE HEX 1 5/16 UN2B 1 035300418

BRACKET PIPE SUPPORT

22 2 035303105
400/175AC

PIPE WITH FLANGE,MOF

23 1 035303167
450/150

24 BRACKET OIL FILTER 1 035303169

25 HOSE SET ASSY 400-175AC 1 035400688

26 O RING ID45.0X3.0 1 220472600

27 OIL FILTER ELEMENT-75 LPM 2 B004800770001

1 BSP BONDED SEAL WASHER

28 1 000959439
VITON

29 O-RING ID47.2X3.5 2 015400891

30 O - RING ID60.0X3.0 2 030449650

31 O-RING ID56.7 X 3.5 1 035400187

ADAPTER;HOSE;1/4 BSPX 1/4

32 1 220370680
NPT

33 ELBOW,HOSE ADAPTER 1/4 1 B010506360046

Parts Manual 11.2

12.0 Trolley system
[ Ref : 035303102 - X031346] PG 400-175 AC

Parts Manual 12.1

12.0 Trolley system
[ Ref : 035303102 - X031346]

Sl.
Description Qty. Part Number
No.

1 SLOW SPEED TROLLEY 1 035303097

2 LIFTING BAIL 1 035302662

3 BOLT HEX M16X45 6 000906215

4 M16 SQUARE WASHER 4 035400867

5 WASHER SPRING M16 6 000996116

6 RUBBER BEADING 0.6 000468500

7 M16 PUNCHED WASHER 2 000996061

Parts Manual 12.2

13.0 Canopy system
[ Ref : 035301770 -X031070] PG 400-175 AC

Parts Manual 13.1

13.0 Canopy system
[ Ref : 035301770 -X031070]

Sl.
Description Qty. Part Number
No.

CANOPY ASSY 1 035302663

1 PANEL FRONT LEFT 1 035302664

2 PANEL FRONT RIGHT 1 035302665

3 BOTTOM PANEL LEFT 1 035302668

4 BOTTOM PANEL RIGHT 1 035302669

5 PANEL REAR LEFT 1 035302666

6 PANEL REAR RH 1 035302667

7 PANEL CENTER RIGHT 1 035303603

8 PANEL ROOF 1 035302675

9 DOOR ASSY 4 035303604

10 PANEL CENTER LEFT 1 035303606

11 PANEL REAR 1 035302674

12 PANEL FRONT 1 035302673

13 MUD GUARD 2 035302676

14 POCKET HANDLE 4 030496310

15 LOCK - HINGED DOORS 8 000921500

16 HINGE (MODEL :DHIM 10076) 8 -

17 LADDER ASSY 3 035400642

18 LADDER 1 035400584

19 SPRING WASHER M8 32 000996108

20 Plain Washer-M8 32 000996008

21 Hex Bolt M8x20 8 000906115

22 Allen Bolt M8x25 32 000983084

23 BOLT HEX M8X25 8.8 ZYP 5-8M 24 000906116

24 HANDLE 2 030496310

25 Hex Nut-M6 4 000948007

26 Allen Bolt M6x20 4 000983064

27 SPRING WASHER M6 4 000996106

Parts Manual 13.2

14.0 Control system
[ Ref : 035302734 - X031277] PG 450 - 150

Parts Manual 14.1

14.0 Control system
[ Ref : 035302734 - X031277]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

NIPPLE; HEX; REDU;

1 VALVE ASSY, PR REG,1/4”NPT 1 A970030 34 220370490
3/4"X1/2"NP

2 NIPPLE HEX 1/4”NPT 2 22037903A 35 BLOW DOWN VALVE 1/2” 1 A010042

3 MOISTURE FILTER 1/4” 1 B442501 36 SILENCER BDV 1/2” 1 035400226

ADOPTER: HOSE 1/4” BSP X

4 4 220370680 37 SCREW M4 X16 2 000985485
1/4”NPT

5 PLAIN WASHER M 12 1 000996012 38 NUT M4 2 000948005

6 PLAIN WASHER M 8 3 000996008 39 BRACKET CABLE HOLDER AE 1 035400686

7 SPRING WASHER M8 1 000996108 40 MUFFLER AIR EJECTOR 2 22041355A

8 PLAIN WASHER M 8 1 000996008 41 HOLDER, CABLE ACT. SIDE 1 035305367

9 HOSE ADAPTER , TEE 1/4 1 B010506360048 42 MANIFOLD CROSS 1 B010506780001

10 HOSE ADAPTER,BRANCH TEE 1 1 B010506360047 43 HOSE ADAPTER 90 DEG 4 B010506360046

11 PLATE ACTUATOR,S16 1 220473630 44 - - -

12 SPRING WASHER M8 6 000996108 45 CABLE SET , CONTROL 6BTA 1 B016206800008

13 SPRING WASHER M6 5 000996106

14 SPRING WASHER M10 4 000996110

15 HEX BOLT M8 X 30 2 000906117

16 HEX BOLT M8 X 40 1 000906119

17 HEX BOLT M10 X 30 2 000906145

18 HEX BOLT M6 X 25 2 000906087

19 HEX BOLT M6 X 16 2 000906084

20 HEX BOLT M8 X 25 1 000906116

21 LEVER,BUTTERFLY VALVE 1 035401219

22 HEXNUX – M6 3 000948007

23 HEXNUX – M10 2 000948010

24 HEXNUX – M8 4 000948008

ACTUATOR ASSY SINGLE

25 1 A030006
ACTING

26 ACTUATOR PIN 1 035401110

27 TEE;PIPE;1/4”NPT 2 22047680A

ORIFICE CONTROL 1/8 X

28 1 035400210
1/4NPT 2.5

29 FIP LEVER ACTUATOR 1 035400463

TL999LL X 1 X0034BSTDO10VT
30 1 B171901
TSW

31 BRACKET, CABLE HOLDER ENG. 1 035400687

32 - - -

ADAPTER TEMP SWITCH VT-

33 1 030449400
TL999L/

Parts Manual 14.2

15.0 Instrumentation system
[ Ref : 035304348 – X031712] PG 400-175, PG 400-175 AC, PG 350-200

Parts Manual 15.1

15.0 Instrumentation system
[ Ref : 035304348 – X031712]

Sl.
Description Qty. Part Number
No.

1 TEMPERATURE GAUGE 1 B202101

2 PRESSURE GAUGE (0-25) 1 B002106840004

3 FUEL LEVEL GAUGE 1 031406020

4 PANEL BOARD 1 035303876

5 IGNITION KEY CIL 1 CUMMINS SCOPE

6 TWO WAY BALL VALVE 1 B003106100003

7 SUPPORT CLAMP 1 035400904

8 MANIFOLD—LOAD VALVE 1 035401171

9 HEX; REDL 3/8” X 1/4” 1 22037897C

10 PLUG; HEX 1/4” NPT 1 22037905B

Parts Manual 15.2

Recommended spares
S. No Description Part Number Qty.

1 Kit, Air filter B574602 1 Set.

2 Kit, Oil filter B004800770001 2 Nos.

Separator element 450-150, 400-175,350-200,
3 010452250 1 No.
380-200, 400-150

4 Separator element 600-100 B006700770009 1 No.

5 Kit, Air filter (Primary element, Secondary element) B574602 1 Set.

6 Indicator, Air filter clog 220413130 1 No.

7 Kit, MPV 220371399 1 No.

8 Kit DCV 220311539 1 set

9 Kit, Oil stop valve 220310329 1 No.

10 Kit, Single acting actuator 220271909 1 Set.

11 Kit, Blow down valve 220460459 1 Set.

12 Kit, Pressure regulator 220317599 1 Set.

13 Drive coupling element - 450/150 B005400900009 1 No.

14 Drive coupling element - 350/200 B005400900018 1 No.

15 Drive coupling - 400/175 B005400900014 1 No.

16 Drive coupling element - 600/100, 380/200, 400/150 B005400900008 1 No.

Kit Details 16.1

Lubrication receiver tank.

Oil performs a very critical function in the oil flooded screw Proposed Drain Period - Mineral oil
type air compressor. This takes away major part of the
S.
heat of the compression, seals all the areas and lubricates Description Drain period
No
bearings and gears. The major criteria in a good quality
Normal industrial application
lubricant for screw compressor are
1. with max operating temperature 1000 hours
a) Viscosity 95 deg C

b) Wear characteristic Industrial application with dusty

2. 750 hours
environment
c) Demalcibility
Engine driven compressor used
d) Heat resistance for Water well drilling and mining
3. up to 200 PSIG - operating 500 hours
e) Thermal stability
temperature
Elgi Airlube is blended using heavy-duty hydraulic based 95 deg C and below
oil with proper amount of additives and strict quality
control check of every batch footprint ensures satisfactory All the above figures are guidelines based on extensive
compressor performance. trials in the field. However, our Service Engineers can help
you to optimize the oil drain interval for your application
Life of mineral oil is covered by operating temperature for
based on the operating temperature, pressure and the
every +10 deg C of temperature beyond 95 deg C. Life of
environment condition.
oil goes down by almost 30-40%. It is recommended that
oil change frequency could be vary between summer
months and winter months to get best out of the mineral
oil and compressor. For this, a good record of operating
temperature of compressor is essential. Continuous
operating of compressor at high temperature beyond
1000C without changing the oil will lead to varnish
formation and will affect the life of bearings and air end.

RECOMMENDED ELGI OIL

ELGi oil Oil change ELGi part Contained

grade frequency number volume

AIR LUBE 500 hours 000998043 210 Litres

00099805A 20 litres
AIR LUBE 00099805B 50 litres
1000 hours*
PLUS
00099805C 210 litres

000998053 20 litres

AIR LUBE XD 1500 hours* 000998054 50 litres

000998055 210 litres

* For operating temperature above 90 deg C and dusty

atmospheric conditions, recommended oil change
frequency is 750 hours.

All the above figures are guide lines based on extensive

trials in the field. However our service engineers can help
you to optimise the oil drain interval for your application
based on the operating temperature, pressure and the
environment condition.

The Discharge Temperature Switch is fitted on the panel.

It shuts down the compressor if the discharge air-oil
mixture temperature reaches the preset value of 115 ±5°
C . The probe is fitted on the airend outlet cover or

Kit Details 16.2

6BT TROLLEY

CS 15.12.12 CONTROL CIRCUIT

JB 15.12.12

0 3 8 3 6015 4
1:1 1 2 R 0 3
6BT TROLLEY

CS 15.12.12 CLUSTER PIN CONFIG

JB 15.12.12

0 3 8 3 6015 4
1:1 2 2 R 0 3
Branch offices

"ELGI HOUSE" 2, Mill Officer's Colony, Behind La-Gajjar Chambers, (Old Reserve Bank), Opp. Times of India, Ashram
AHMEDABAD Road, Ahmedabad - 380 009, Tel: +961-79- 26583736, 26581274, 26587683, Fax: 91-79-6587683,
E-mail: [email protected]

BANGALORE 15,16 Richmond Road, Bangalore - 560 025, Tel: +91-80-22537208, Fax: 91-080-22293274, E-mail: [email protected]

S4-II Floor, Apollo Dubai Plaza, No-100, Mahalingapuram Main Road, Nungambakkam, Chennai - 600 034,
CHENNAI
Tel: +91-44-28172599, 28179500, Fax: 91-44-28174699, E-mail: [email protected]

1st Floor, No.622-A, Near ELGi industrial Complex, Trichy Road, Singanallur, Coimbatore - 641 005,
COIMBATORE
Tel: +91-422-2589555, Fax: 91-422-2573697, E-mail: [email protected]

H.NO: 12-13-188, II nd Floor, Street No. 2, Taranaka, Hyderabad - 500 017,

HYDERABAD
Tel: +91-40-27000435, 27000437, 27000439, 27000431, Fax: 91-40-27000438, E-mail: [email protected]

602, 6th Floor, Diamond Tower, Purani Chungi, Ajmer Road, Jaipur - 302 021,
JAIPUR
Tel: +91-141-2970120, 2970121, E-mail: [email protected]

1st Floor, Asset Summit Suites, National Highway 47, Near SCMS, Kalamassery, Kochi – 683106.
KOCHI
Tel: +91-484 -2360155, 2351904, E-mail: [email protected]

Space No. 502, Block - C, 5th Floor, Axis Mall, Action Area - 1C, New Town, Premises No. CF - 9, Kolkata - 700 156,
KOLKATA
Tel: +91-33-2324-4270, 2324-4271, Fax: 91-33-2324-4272, E-mail: [email protected]

Marol Co-op Industrial Estate Ltd. Plot No.48, Mathurdas Vassanji Road, Near Sakinaka, Andheri (East), Mumbai-400 059,
MUMBAI
Tel: +91-22-42161000, Fax: 91-22-28591601, E-mail: [email protected]

23, Shivaji Marg, Near Karampura, Opp.DCM, New Delhi - 110 015,
NEW DELHI
Tel: +91-11-25928095, 25153644, 25175018, Fax: 91-11-25459375, E-mail: [email protected]

White House, Ground Floor, 388/A-1/2240, Mumbai - Pune Road, Opp. Sandvik(Asia), Dapodi, Pune - 411 012,
PUNE
Tel: +91- 20-30635457, Fax: 91-20-4073759, E-mail: [email protected]

Om1, 1st Floor, Ashoka Milllennium, Ring Road No.1, Raipur - 492 003, Chhattisgargh,
RAIPUR
Tel: +91-97520 93008, Fax: 91-771-4073759, E-mail: [email protected]

4/2, Nandhini Complex, 1st Floor, Velur Road, Tiruchengode - 637 211,
TIRUCHENGODE
Tel: +91-4288-257137, Fax: 91-4288-257693, E-mail: [email protected]

Overseas offices

ELGI EQUIPMENTS LIMITED, No.7, Jalan Anggerik Mokara 31/44, Sek. 31, kota kemuning, 40460 Shah Alam, Selangor,
MALAYSIA
Malaysia, Tel: +603-5120-1544 Web: www.elgi.com.my

ELGI EQUIPMENTS LIMITED, 223/66, 14th Floor, Building A, Country Complex, Sanphawut Road, Bang Na, Bangkok,
THAILAND Thailand - 10260, Tel: +6627455160, Local Use: 02-7455160,
E-mail: [email protected], Web: www.elgi.co.th

Overseas fellow subsidiaries

ELGI EQUIPMENTS PTY LTD., Unit 1, 33 Kingsbury Street, Brendale Queensland - 4500. Australia,
AUSTRALIA Tel: +61 7 3106 0589, Fax: +61-7 3106 0537, Email: [email protected],
Web: www.elgi.com.au

ELGI COMPRESSORES DO BRASIL LTD, Av. Emílio Chechinatto, 4195 – Bairro São Roque da Chave,
BRAZIL
CEP:13.295-000, Itupeva – São PauloBrasil, Tel: +55-11-4496 5519, 4496 6611, E-mail: [email protected]

ELGI EQUIPMENTS (ZHEJIANG) LIMITED, West of 1st Floor, Building 2, No. 232, Yunhai Road, Jiaxing 314033 P.R. China,
Tel: +86-573-82079100, Hotline: 400-826-3585 E-mail: [email protected], Web: elgi.cn
CHINA
ELGI COMPRESSORS TRADING (SHANGHAI) CO.,LTD. Rm 912-913, No. 8-9, Lane 1500, South Lianhua Road, Shanghai
201108 P.R. China, Tel: +86-21-33581191, Hotline: 400-826-3585, E-mail: [email protected], Web: elgi.cn

PT ELGI EQUIPMENTS INDONESIA, Kawasan Pergudangan, Bizpark Commercial Estate, Pulogadung Jl, Raya Bekai Km.
INDONESIA 21, 5 Block A3 No. 12, Kel. Rawa Terate, Kec. Cakung, Pulogadung Jakarta Timur 13920,
Tel: +62-21- 46822216, 46827388, E mail: [email protected], Web: www.elgi.co.id

ROTAIR Spa, Via Bernezzo-67, 12023, Caraglio (CN), Italy, Tel: +39 0171619676, Fax: +39-0171619677,
ITALY
E-mail: [email protected], Web: www.rotairspa.com

ELGI GULF FZE, PO Box: 120695, P6-27, SAIF Zone, Sharjah, U.A.E. Tel: +971 6 557 9970, +971 50 457 6470,
MIDDLE EAST
Fax: +971 6 557 9980, E-mail: [email protected], Web: www.elgigulf.com

ELGI COMPRESSORS USA, INC. 1500 Suite N Continental Blvd, Charlotte, NC 28273, USA. Tel: +1-704-943-7966,
USA
E-mail: [email protected]
FACTORY & REGISTERED OFFICE
ELGI EQUIPMENTS LIMITED
Singanallur, Coimbatore - 641 005,
India (CIN:L29120TZ1960PLC000351).
Tel: +91-422-2589555
Fax: +91-422-2573697, +91-422-2589401
E-mail: [email protected], Web: www.elgi.com

ELGI EQUIPMENTS LIMITED (FOUNDRY DIVISION)

SF No: 212/1A, 213/1, KodangipalayamVillage,
Nallatipalayam Road, Singarampalayam Post, Kinathukkadavu,
Kinathukkadavu Taluk,
Coimbatore - 642 109, India.
Tel : +91-422-2587631, 620

GLOBAL SUPPORT CENTRE

SF NO 221, 221/2 & 221/3, Kothavadi Road,
Kodangipalayam Village, Singarampalayam(PO),
Kinathukkadavu Taluk,
Coimbatore - 642 109, India.
Tel : +91-422-2587000.

ELGI EQUIPMENTS LIMITED (AIR COMPRESSOR PLANT)

SF NO 221/1 to 3 - 229/B1, B2, B3, 232/B1,B2, 234/B1, 264/B1 and 264/B2.
KothavadiRoad, Kodangipalayam Village,
Singarampalayam (PO) Kinathukkadavu
Taluk, Coimbatore - 642 109, India.
Tel : +91-422-2587000.

FELLOW SUBSIDIARIES (DOMESTIC)

ATS ELGI LIMITED,
Kurichy Private Industrial Estate, Kurichy,
Coimbatore - 641 021, India,
Tel: +91-422-2589999, 2672201-3,
Fax: +91-422-2675446,
E-mail: [email protected],
Web: www.ats-elgi.com

ADISONS PRECISION INSTRUMENTS MFG.CO.LIMITED

Elgi Indusrial Complex, Singanallur,
Coimbatore - 641 005
Tel: +91-422-2589555

ERGO DESIGN PVT LTD,

150, 2nd Main, 2nd Cross, Chelekare, Kalyan Nagar,
Bengaluru, Karnataka 560043,
Tel: +91-80-42436000

JOINT VENTURE
ELGI SAUER COMPRESSORS LIMITED,
Elgi Industrial Complex III, Singanallur,
Coimbatore - 641 005, India,
Tel: +91-422-2589555, 2589634, 2589510,
Fax: +91-422-2573697,
E-mail: [email protected], Web: www.elgisauer.com

INDUSTRIAL AIR SOLUTIONS LLP,

1, R R Industrial Estate, Opposite Shanthi Gears Regd Office, Singanallur,
Coimbatore, Tamil Nadu 641005,
Tel: 0422 227 1862.

DIVISION
PRESSURE VESSEL DIVISION
1473 - Trichy Road, Coimbatore - 641 018,
Tel: +91-422-2589777,
Email: [email protected].

