ELGI ELGI EQUIPMENTS LIMITED -DIESEL POWERED SCREW AIR COMPRESSOR SKID-MOUNTED TWO STAGE HIGH PRESSURE OPERATION AND MAINTENANCE MANUALnn Section Il Maintenance Page No 4 General. 11.0 12 Daily Operation... 11.0 11.3 Maintenance after initial 100 hours of running. 11.4 11.4 Maintenance After every 500 hours of running... 4414 44.5 Maintenance above 500 hours of running ... 144 44.8 Components Maintenance and Replacement Procedure 11.6.1 Oil Filter 11.2 11.6.2 Separator Element . 11.2 11.6.3 Air Inlet Filter .... 11.6 11.6.4 Drive Coupling ..... 11.6.5 Control System Adjustment...... 11.10 44.6.6 Minimum Pressure Valve ..........-- 11.10 11.6.7 Oil Stop Valve....... 11.14 11.6.8 Blow Down Valve 11.16 11.6.9 Discharge Check Valve 14.16 11.68.10 Pressure Regulator Valve .. 14.18 11.6.11 Single Acting Actuator 11.20 Section 12 Trouble Shooting .... 12.0 Section 13 Recommended Spares 13.0 13.4 Kit of Spares ........... 13.1List of Figures Fig 1 2 20 21 bt ELG Page Nos Photograph of DZ 23 036 (900/350) Model......... 4.0 Photograph of DU 23 040 (1000/275) Model.. 42 Steps in compression by typical helical lobe rotary Compressor... ‘Schematic diagram of two stage high pressure compressor Air Inlet system... Mode of operation - Start Mode of operation - Normal running sciicinaseecaonnsicnisenasenias 8 Mode cf Operation - Modulating .. Mode of operation - Shut down... Discharge System Cooling and Lubrication System..... Electrical Circuit diagram ...... Instrument Panel.......... Oil Filter - Main/Bearing Inlet Air Filter. Minimum Pressure Vaive ... Oli Stop Valve ... Blow Down Valve .. Discharge Check Valve .. Pressure Regulator. Single Acting Actuator cess| ne PREAMBLE 01. Thank you Thank you for purchasing this quality product. This. modern pneumatic machine has been designed to provide you with many hours of useful service. This Operation and Maintenance Manual provides you with easy- to-understand operating instructions. Read.the entire manual and follow all the instructions to keep your new pneumatic machine in top operating condition. This manual comprises of a parts list in addition to a recommended spares list, providing you information that you need to order parts. 02. Product References, Illustrations and Specifications All information, illustrations and specifications in this manual are based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. _ 03. Service Information Service on this pneumatic machine within and after the warranty period, can be performed by any ELGI branches and authorised distributors / dealers. To obtain the listing of ELGI Branches and Authorised Distributors/Dealers in your area, DIAL + 91 - 422 - 2574691 FAX + 91 - 422-- 2573697 MH. USERS’ IMPORTANT INFORMATION Ol. Attend to any signs of minor irregularities immediately. If neglected, they could become worse. 02. In case of any requirement of spares or service, please contact our nearest branch office or distributor / dealer. Spares will be supplied only through-branches and distributors/dealers. 03. Retain this manual carefully throughout the life of the equipment, in order to procure correct spares. 04. While ordering spare parts the following particulars must be clearly mentioned to ensure supply of the right spares. L Model 2. Fabrication number 3. Year of manufacture Eo |NOTE cae eee 4. Parthaime 0 Proof of purchase will be required for warranty service i Drawing number a Make sure this manual is read & carefully understood | | i before starting /operating this machine 6. Required quantity 05. Due to improvements being made constantly and continuously, the illustrations and descrip- tions in this manual are not binding.by cE fo] i wa. FOREWORD This Screw air compressor has been designed and manufactured with utmost skill and care with maximum reliability and high quality standards as per the requirements and specifications conforming to International Standards. All the equipment and materials that go into its manufacture have undergone rigorous quality assurance checks. Strict vigilance and stringent measures have been observed to maintain high standards of quality, right from raw material purchase, inspection, manufacturingand operation to the capacity trials conducted at our factory and finally packing and despatch. The various materials that are used for its manufacture have been carefully selected for their apt application; keeping in mind their strength, reliability, safety requirements, working conditions and working media. The design incorporates maximum safety measures and protection against all hazards during the operation of the system. This manual has been prepared and compiled with utmost care to help the user to know the various systems involved in the compressor thoroughly and to operate it to his best advantage. Itincorporates detailed description of all systems and working conditions with relevant diagrams and drawings. Before attempting to use the compressor, the user shall go through this book carefully to get acquainted with this equipment to ensure best results. Under normal working conditions and with regular prescribed periodic preventive maintenance, excellent, trouble free service can be guaranteed for several years. In case of necessity, our service can always be counted upon1 USER INFORMATION 1.1 General Ensure the Compressor is lifted by using the lifting Eye provided in the Lifting Bail only Ensure the Operation , Instruction Manual be madé available to the compressor operating personnel at all time. Please read the instructions carefully and strictly adhere to it till the end as the operating life and the reliability of the Compressor depends to a large extent on correct operation and maintenance. While communicating with ELGI Dealers/Service Centre/Rranch Office regarding the Compressor you have, ensure all the details on Name Plate(format shown below) are given. The name plate is fitted on the front side of the Compressor base frame. For ordering spare parts refer "Recommended Spare Parts" chapter and provide Part Number along with quanitity in addition to.the name plate data of Compressor. ELGI-EGUIPMEN Becere) i=). vre)st aaa ee >t Ch eee (ay CY Fae A: — NE areal i _ Given tee ; 1.2 Warranty ELGI does-not accept any liability for damages in transit and handling in transport. Please inspect the Compressor immediately after delivery In the event of any other complaints, please inform us within six days , after the receipt of consignment. Preserve the Guarantee Certificate sent along with the-Compressor safely Elgi cannot accept any guarantee for damages resulting from failures to observe the operating instructions given in this manual. The guarantee will also expire if you alter the Compressor yourself in any way, performing improper repairs or insufficient maintenance. Appropriate repair and maintenance also involve the exclusive use of Elgi Genuine Spare Parts except Engine parts and ELGI operating materials For appropriate repair and maintenance of engine, use genuine spare parts supplied by Engine Manufacturer. For regular service checkup and warranty claims contact the nearest Authorised Service Centre of the Engine Manufacturer We reserve the right for modification without notice in the interest of technology progress 1.01.3 4.4 ri B im es Handling Compressor . Lift the conipressor using the lifting bail . Prior to lifting, inspect lifting bail and points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts and nuts + Make sure entire lifting, hook has a functional safety latch, or equivalent, andis fully engaged and latche‘ on the bail + Use guide ropes or equivalent to prevent twisting or swinging of the machine once ithas been lifted clear offthe ground + Donotattempttoliftin high winds Keep all personnel out from under and away fromthe Compressor when itis suspended + LiftCornpressor not higher than necessary + Keep lift operator in constant attendance whenever Compressor is suspended. or Location ident Prevention Regulations when installing this Screw Compressor. Install the Ce apracsor with adequate accessibility to ensure obstruction-free operation and maintenance The area around Compressor should be clean, dry, coo! and free of dust. Excessively warm intake air affects the compressed air output. The ambient temperature should not drop below +5°C ‘The radiator and oil cooler side of the compressor should be kept at a minimum distance of one meter from ructions. If operated in an enclosed 2rea ensure proper ventilation for the exh store combustible materials within at least 10 m radius of Compressor. The floor * also must be of non-combustible material, frontal ob ist gases. New round Como Compressor Installation While installing the compressors, ensure the followi 4 Keep vibration absorption pads of minimum 10mm thickness (for the entire length of compressor skid base frame) between compressor base frame and the truck chasis top surface while mounting the skid on the truck. This is to ensure the skid is supported with uniform contact area and vibrations generated are absorbed. 2. Provide spring washers between nut and clamp piece (used for holding skid base frame to truck chasis with U-bolts) to ensure the nuts do not get loosened due to vibrations. 3. Keep clearance space of §00 mm around the compressor for maintenance . 4. Keep 1000 mi distance between cabin back wall of the truck and oil cooler side Llcover to ensure cool air is sucked. No material should be kept in front of cooler side cover. If you fail to observe the information concerning installation anc ventilation, the discharge temperature of Compressor may increase or decrease excessively and trip-off the Compressor at high discharge temperature conditions. The output of compressor also will be affected. The compressor will not give warnings during short operating times. It will operate below dew point and moisture condensate will mix with oll. This will reduce the lubricating qualities of oil and lead to damage to the CompressortH LG SS = 2.0 SAFETY ELGI designs and manufactures its products for smooth and safe operation. However, the responsibility of safe operation rests with those who use and maintain these products. Following safety precautions and devices are offered as guide and accessories respectively. These when followed will minimise the accidents and failures through out the useful life of the equipment Only those who have been trained and delegated to do so and who have read and understood this OPERATION AND MAINTENANCE MANUAL should operate the air Compressor. Failure to follow the instructions, procedures and safety precautions given in the manual may increase the possibility of accidents and failures. Refer Operation and Maintenance Manual of Engine and follow the instructions as given by the Engine Manufacturer. Never start Air Compressor unless it is safe to do so. Do not attempt to operate the air compressor with known unsafe condition. Tag the air compressor and render it in-operative by disconnecting power supply so others who may not know of unsafe condition will not attempt to operate it until the condition is corrected This ELGI Screw Compressor is not explosive-proof and not to be operated in explosion area. Do not modify Compressor except with written factory approval Pressure Release 1. Manually pop up the pressure relief valve when the Compressor is operating, at least weekly, to make sure'the pressure relief valve is not blocked, closed, obstructed or otherwise inoperative. 2. Do not use tools that are rated below the maximum rating of this Compressor. Select tools, air hoses, pipes, valves, filters and other fittings accordingly,Do not exceed manufacturer's rated safe operating presssure for these items 3. Secure all hose connections by wire, chain or other suitably retaining devices to prevent tools or hose ends from being accidentally disconnected. 4. Open oil filter cap only when compressor is not running and is not pressurised. Shutdown the compressor and bleed the receiver tank to zero internal pressure before removing the cap 5. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug connection or other component, such as filters. 6. Keep personnel out of line with and away from the discharge opening of hoses or tools or other points of compressed air discharge. 7., Do not use air at pressure higher than 2.5 kgf/cm? for cleaning purposes. 8. Do not engage in horseplay with air hoses as death or serious injury many result. 20Fire and Explosion A. Clean-up spills of lubricant or other cumbustible substances immediately, if such spills occur. Shut-off the air compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and do not permit smoking in the vicinity when checking or adding oil/fuel Do not use flammable solvent for cleaning purposes Keep electrical wiring and other terminals in good condition. Replace any wiring that has cracked, cut, abraded or otterwise with 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 proper flow of cooling air/cooling water or with inaequate flow of lubricant or with degraded lubricant. Do not attempt to operate the Compressor in any classificat.on of hazardous environment unless the Compressor has been specially designed and manufactured for explosive applications Moving Parts 1. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other moving parts. Do not attempt to operate the Compressor when the fan guard, coupling guard or other guards removed Wear snug fitting clothing and confine long hair when working around this Compressor, especially when exposed to hot or moving parts. Keep access doors, if any, closed except when making repairs or adjustments Make sure all personnel are out of and / or clear of the Compressor prior to attempting to start or operate it . Disconnect and lock out all power at source and verify at the Compressor that the circuits are de-energised to minimise the possibility of accidental start-up or operation, prior to attempting repairs or adjustments. This is especially important when Compressor is remotely controlled. Keep hand , feet, floors, controls and walking surfaces clean and free of fluid, water or other liquids to minimise the possibility of slips and falls. 21tH BE Q = Hot Surfaces 1. Avoid bodily contact with hot oil, hot coolant, hot surfaces. 2. Keep all parts of the body away from all points of air-discharge. 3. Wear personal protective equipment including gloves and head covering when working in, on or around the Compressor 4. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. Don't ignore small cuts and burns as they may lead to infections. Toxic and Irritating Substances 1. Do not use air from this Compressor for respiration (breathing) 2. Operate the Compressor only in open or well ventilated areas. 3. Oils, coolants and lubricants used in this Compressor are typical of the industry . Care should be taken to avoid accidental ingestion and/or skin contact. In the event of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin contact . DANGER Death or serious injury may result from inhaling compressed air without using proper safety equipment 22SE Entrapment + 2 + Make sure all personnel are out of compressor before closing and latching enclosure doors. If the compressor is large enough to hold a man, and if itis necessary to enter it to perform service or adjustments, inform other personnel before doing so, or else secure the access door in the open position to avoid the possibility of others closing and possible latching the door with personnel inside Jump Starting He Observe all safety precautions mentioned elsewhere in this manual. Batteries may contain hydrogen gas, which is flammable and explosive. Keep flames, sparks and other sources of ignition away. Batteries contain acid, which is corrosive. Do not allow battery acid ‘o contact eyes, skin, fabrics, or painted surfaces as serious persona! injury or property damage could result. Flush any contacted areas thoroughly with water immediately. Wear an acid resistant apron and face shield, when attempting to jump-start the compressor. Remove all vent caps from thie battery or batteries in the compressor. Do not permit dirt or foreign matter to enter the open cells. Check fluid level , if low, bring fluid to proper level before attempting to jump start. Do not attempt to jump start if fluid is frozen or slushy. Bring batteries up to atleast 4- deg F (5 degC) before attempting to jump start Cover open celis of oil compressor batteries with clean dampened cloths before attempting to jump start Attempt to jump start only with a vehicle with a negative ground electrical system with the same voltage and that is equipped with a battery or batteries of comparative size or larger than supplied with the compressor. Do not attempt to jump start using motor generator sets, welders or other sources of DC power as serious damage may result. Bring the starting vehicle alongside the compressor, do not permit metal to metal contact between the compressor and the starting vehicle Set the parking brakes of both the compressor (if provided) and the starting vehicle or otherwise block both sides of all wheels Place the starting vehicle in neutral or park, turn off all non-essential electrical loads and start its engine. Use only jumper cables that aré clean, in good condition and are heavy enough tohandle the starting current. 2313. 14. 15. 16. 18 rd LG Lal Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to minimise the possibility of uncontrolled arcing which might serve as a source of ignition Positive battery terminals are usually identified by a plug (+) sign on the terminal and the letters POS adjacent to the terminal. Negative battery terminals are usually identified by the letters NEG adjacent to terminal. Check your connections. Do not attempt to start a 24V compressor with one 12 V battery in the starting vehicle. Do not apply 24 V battery in the compressor . Connect the other end of this same jumper cable to a clean portion of the compressor engine block away from fuel lines, the crank case breather opening, and the battery. Start the compressor in accordance with normal prodcedurc. Avoid cranking more than 5 seconds continuously. Remove and carefully dispose of the dampened cloths, as they may be contaminated with acid, then replace oil vent capsDO’S AND DONT’S bo’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. Maintain correct oil level Use proper tools Attend immediately to anything unusual with the air compressor. DON'TS * Neglect the routine attention. “Allow any leakage in the system. Keep any tools or loose items on the compressor / other modules. — Meddle with any adjustments or settings. * — Use cleaning agents, when changing oil ” Overload the compressor for a long period even though it is of continuous rating, as we recommended intermittent use only. 3.0ELGI Fig 1 4.0eee 4.0 SPECIFICATIONS & SALIENT FEATURES 4.1 Technical Specifications No Description Unit DY 23 044 01. Free airdelivery etm 1100 m/min 31.15 02. _ Working pressure kgtiom? 21 psi 300 03. _ Engine Make ‘OL 04. Engine Model NTA 855C Big Cam JOS. _ Max. operating speed tm 1900 06 __Min operating speed pm 1100 07 _ Engine power output HP. 430 08 Engine lube oil capacity litres 53 09 Engine cooling water capacity litres 2t | |10__ Battery quantity _ No 2 ee et 11 Battery capacity AH 180 12 _ Coupling Model 2613 2800 Series 13 _CouplingMake VULKAN 14 _ Fly Wheel housing SAE 4 15 _ Fantype & Diameter mm SUCKER 1267(42") 16 Compressor oil cooling system Aircooled 17__Air-oil separator tank capacity litres 440 18 _Oilfill capacity (first fill) litres 140 19 _ Temperature of outlet air DegC Amb+70 20 Air outlet port size Inches & 2%, 1No Qty 21__Overall dimensions of Package mm 4562x1794 x 2070 22. Net weight kgemer Fig 2 ly Lal 424.2 Salient Features Less Maintenance ‘A Screw Compresscr has only two moving parts - the rotors which do not touch each other as they are kept apart by means of a thin film of oil and hence there is not wear and tear. No reciprocating parts like piston, piston rings, connecting rod and no suction or discharge valves to be maintained. Maximum Reliability Only two moving rotors at conservative speed provide reliability never before attained in the history of compressor industry. . Small Package Because of the unique way the screw compresses the air, a complete air package is provided in small overall dimension with,factory tested and ready to use condition. Long Life & No loss in capacity Since there is no metallic contact between rotors and housing and flooded with oil, no wear or reduction in output capacity/performance will occur even after many years of operation Pulsation-tree Flow The continuous flow of ait through helical cavities'in the screw and continuous compression ensures pulsation-free compressed air delivery. = Air Quality The unique OSBID Air-Oil separation system provided ensures efficient separation of oil particles with minimum pressure drop from compressed air-oil mixture delivered at compression end. The OSBID system ensures consistent quality of air during normal running and unloading cycles. 4.3fi Es Q x 5.0 COMMISSIONING 54 5.2 General The operating instructions given below are for commissioning of standard version Air cooled Compressors without additional equipment. Before commissioning the equipment check for visual damages of parts. An Electrical circuit diagram is delivered with every Compressors (kept inside Electrical control panel) for electrical wiring reference. Every Screw Compressor is subjected to test run and set prior to despatch. Transport damage at a later stage cannot however be excluded. Therefore, please observe the compressor closely during commissioning and trial run Instructions for commissioning work + Remove the transport security bolts / clamps fitted on Compressor = Connect the Compressor to the air network Check oil level in the receiver tank before starting the Compressor. The oil level should be up to the top level of the oil sight glass provided on the receiver tank The first oil fill capacity of the compressor is as below and when receiver tank is empty 120 litres for all the models Use Elgi Air Lube Oi! for the best performance of your Compressor Part No. : 000 9 9804 3 SPECIALLY FORMULATED MINERAL OIL FOR SCREW AIR COMPRESSORS ‘ Check and ensure the oil filter cartridge is fitted properly Keep the air outlet line ball valve provided on the front side of the compressor in fully open condition before starting the Compressor : Check engine oil level by removing the dipstick provided on the engine block . Check water level in the radiator. a Check diesel in the diesel tank + Check battery connections + Check oil in the fuel injection pump Ensure authorised electricians only carryout the electrical work. Study electrical circuit diagram before starting work. 50Clockwise rotation of Engine viewed from fan side must be ensured Switch ON the power supply switch provided on the instrurnent panel Turn the ignition key and press the override button simultaneously for not more than 5 secs Release ignition key and override button as soon as the engine fires. If engine does not start within 5 secs., release the ignition key and override button Restart after an interval of one minute Run the unit for 15 to 20 minutes and check for leakage. All the settings for pressure regulator, electrical protection devices etc., are set at factory during testing before despatch In case of abnormal noise observed during running of of Compressor, immediately switch OFF the Compressor and contact the ELGI Service Engineer for remedy. All above points to be adhered to during re-installation of Compressor from one location to the other . If Compressor is stored for longer period before commissioning, contact ELGI Service ‘Engineer for installation and commissioning services.6.0 WORKING PRINCIPLE Air compression achieved in Rotary Screw Compressor in the following manner. Airis admitted atone end of the rotors where the matching lobe and flute first come into mesh as the rotors turn. Continued rotation brings the line of mesh past the air inlet port and then the air in the flute of the female rotor is confined by the lobe of the male rotor and stator. Compression now occurs as the rotors turn further. At the time, the far end of the compression pocket tums towards the discharge port and air flows out in the system, as shown in Fig. 3 on Page No.6.0, which depicts one lobe meshing with one flute. + Theflutes of the female rotor and the lobes of male rotor correspond respectively to the cylinder and piston of Reciprocating Compressor. Lubricating cil is injected into the compressor unit, (here to be referred as air end) which in large quantities mixes directly with the air as the rotors turn compressing the air. + The lubricating oil has four functions a) As. acoolant it takes away the heat of compression b) Seals the leak paths amongst the rotors and housing ¢) — ActS as a lubricating film between the rotors allowing one rotor to directly drive the other without a metal to metal contact, @) Also lubricates the bearings and gears. ) Use Elgi Air Lube Oil for the best performance of your Compressor Part No. : 000 8 9804 3 SPECIALLY FORMULATED MINERAL OIL FOR SCREW AIR COMPRESSORS 61ri lim a mt 0 SYSTEM OPERATION The air aspirated through the air filter is compressed in the Screw Compressor driven by Diesel Engine. The air to the compressor is throttled by the butte-fly valve. The air/oil mixture is delivered to the receiver tank through ‘he discharge check valve which acts like a non return valve Oil and air are separated by "OSBID PROCESS’. "OSBID" process utilises the impact and difference in density to separate the air & oil ‘The separated oil is re-cooled in the oil cooler and is returned to the injection point through the oil filter. This oil circulation circuit, operated solely by the pressure differential, does not require any separate oil pump Final filtration done using ahigh efficiency separator maintaining oll carry-over levels consistently below 10 ppm : Thermal valve provicled in the oil circuit ensur discharge temperature for optimum performance. Qil collected in the receiver tank is cooled by the oil cooler and returned back to the air end through the main oil filter and oil stop valve Compressed air liberated from the air oil separator elementis delivered to the service line through the minimum pressure valve The minimum pressure valve positioned downstream of the oil separator maintains minimum pressure for safety supply of oil to the compressor unit The engine is throttled by the actuator which in turn gets the input air from the receiver tank through the pressure regulator and moisture separator Refer Schematic Diagram for various elements used in the system. 7.0VL Fig 4 Schomatic diagram of two stage high pressure compressor —— AIR/OIL LINE — Olt LINE == AIR LINE1 PARTS LIST Two stage High Pressure SL.No. Description aty 1. Oil Cooler 1 2. Radiator 1 3. Shroud 1 4. Fan 1 5 Engine 1 6. Single Acting Actuator ri 7. Adaptor Ring 1 8. Air Filter (Engine ) 1 9. Air End 1 -10. Air Filter (Compressor) 1 1. Pre Filter 1 12. Pressure Regulator Valve —_ a 13. Moisture Filter 1 14, Blow Down Silencer 1 15. Blow Down Valve — 1 16. Receiver Tank ot - 17. Minimum Pressure Valve 1 18. Ball Valve 1 19. Return Line Oil Strainer 1 20. Return Line Oil Sight Glass 1 21. Pressure Relief Valve 1 22. Oil Fill : 7 23. Oil Level Sight Glass — 24. Gate Valve 1 25. Temperature Gauge 4 26. Flexible Hose 1 27. Temperature Switch 1 28. Discharge Check Valve 1 29 Oil Stop Valve 1 30. Mainoil filter 1 31. Thermal Valve 1 7.28.0 FUNCTIONS OF VARIOUS 8.1 8.2 8.2.4 SYSTEMS Air Inlet System The air inlet system as shown in Fig on Page No.8.0 comprises of a dry type filter, which filters the inlet air and prevents foreign particles from entering the air end. The air inlet valve is of butterfly type which directly controls the amount of airinto the air end. The opening or closing of the valve disc controls the port area in response to the function of a single acting spring- loaded actuator which operates in correlation with the control system. The actuator receives operating pulse from the pressure regulator valve. Capacity Control System The functional description of the capacity control system is described below in 2 distinct phases of operation. This description will apply to all control system with an exception to the pressure set according to your pressure requirements, which can be achieved by adjusting the pressure regulator. The control system for the set pressures will be in accordance with a machine having an operating range of pressures Atypical control system is illustrated in Figures on Page No. 8.2 to 8.5 Start When the compressor is started, the atmospheric air is drawn through the butterfly valve, compressed and discharged to the air/oil receiver. The pressure builds up in the receiver tank from 0 to 4 kgffcm?*. During this period the pressure regulator valve and the actuator are in-operative. The actuator holds the butterfly valve fully open and the compressor operates at full rated capacity. As the compressor operates at full capacity, the engine runs at rated speed. The rising receiver tank pressure is isolated from the service line by the minimum pressure valve, which is set at 4 kgffcm? . 8.2.2 Normal Operation When the receiver tank pressure rises above 4 kig/cm®, the minimum pressure valve opens and delivers, compressed air to the service line. At this time, the actuator remains in-operative, holding the inlet valve fully open for maximum air output, The engine will continue to run at rated speed during this phase of operation. 84ze ENGINE GOVERNOR, BLOW DOWN. ‘SILENCER: NON-RETURN VALVE ‘ - cy) i ENGINE AIREND_ Fig 6 Mode of Operation - Start LOW PRESSURE REGULATOR BALL_VALVE BLOW DOWN, ‘VALVE MOISTURE FILTER HIGH PRESSURE REGULATOR RECEIVER TANK. GER AAR LINE ZA NR/OIL LINEeg CaS ree LOW PRESSURE TLATOR: BALL VALVE BLOW DOWN. VALVE MINIMUM PRESSURE 1—— AIR oumer HIGH PRESSURE REGULATOR Lo \ \ \arene covervon \pnone \ ABB WR/OIL LINE Id'To Fig 7 Mode of Operation - Normal runningve LOW PRESSURE Fig 8 Mode of Operation - Modulating REGULATOR BLOW DOWN * SILENCER, BALL VALVE SLoW_pown, MIRIMUM. PRESSURE NON-RETURN VALVE VALVE VALE ‘ AIR OUTLET MOISTURE FILTER HIGH PRESSURE . ayn mY REGULATO! G5 0 RECEIVER TANK, ENGINE GOVERNOR \ ENGINE | SBS AR LINE AREND (SEE AR/OL UNEse LOW PRESSURE . REGULATOR = * BLOW _DOWN SILENCER, BALL VALVE won =neTURN S1o¥ DOWN anu PressuRE VALVE . VALVE a OUTLET MOISTURE FILTER . in Cr) HIGH PRESSURE o Quy i REGULATOR OF : [ee ik tl li > RECEIVER TANK | ENGINE GOVERNOR \ enoine | GEER ar LINE AIREND (ZB AR/OIL UNE Fig. 9 Mode of Operation - Shut down (SIs8.2.3 Modulation In case of air being used is less than the rated capacity of the compressor, the service line pressure will rise above operating pressure. Now the pressure regulator viave gradually opens, applying pressure to the actuator. This causes the actuator rod to partially close the inlet butterfly valve and reduce the speed of the engine. As the pressure increases, the actuator rod will further close the inlet butterfly valve and continue reducing the engine speed until it reaches loaded speed The actuator has an orifice in its cover which vents a small amount of air to the atmosphere when the pressure regulator valve is open. This allows the actuator to vary the air intake matching the air demand. The orifice also bleeds any accumulated moisture from the actuator. The compressor will continue to run in this manner until air demand increases. As air demand increases, the receiver tank pressure will fall to operating pressure. The pressure regulator valve will close, the air inlet valve will be fully open and the engine will once again run at rated speed. 8.2.4 Shut Down a) The blow down valve is held closed by a pressure signal from the compressor unit. Upon shut down the pressure signal is lost and the blowdown valve opens venting the receiver tank pressure to the atmosphere. Working pressure : 21kg / em? (200 psig) Start mode 0-10 kg / em? Normal operating mode : 20.5 kg / om? Modulating mode : 21-22kg / om? Shut down 5 12-0 kg /om®Ly} ES Q| rt 5 es SSS ‘8. 3 Discharge System * ‘The Compressor discharge system is shown in Fig on Page No.8.8 The Screw Air Compressor discharges compressed ait/oil mixture through a discharge check valve into the receiver tank + Thedischarge check valve prevents the compressed air from returning tothe compression chamber after shut down of the unit The compressed air/oil mixture enters the receiver tank tangentially wherein heavier particles are separated and falls to the bottom of the receiver tank. The separator element at final stage of air oil separation is the vital element for getting clean air outlet. The separated oil collects in the element surface and descends to the bottom of the separator The retum valve (or scavengeline)leads from the bottom of the separator element to the inlet regime of the compressor unit ensures separated oil is retumed to the compressor by the pressure differential between the area surrounding the separator element and the compressor inlet. Nylon tube used in the return line helps in usually checking the oil flow. The minimum pressure valve at the outlet of the receiver tank ensures a minimum receiver pressure of 4kgf/em? during all conditions for proper air/oil separation and proper oil circulation to air end Apressure relief valve (located on the wet side of the separator) is set to open if the receiver tank pressure exceeds 40% more than working pressure Oil to be filled in tho receiver tank through the elbow welded on tank after removing the plug. An il sight glass enables the operator to usually monitor receiver tank oil level WARNING * Do not remove caps, plugs, or other components | when compressor is running or pressurised. | + Stop compressor and relieve all Internal pressure | before doing so B8788. RETURN LINE OL SIGHT CLASS COMPRESSOR “\ ee RETURN UNE OIL, STRAINER MINI PRESSURE VALVE TERMINAL CHECK VANE ol FO AIR OUTLET RECENER TANK LORAIN. GATE VALVE a CHECK VALVE, { BEARING OIL FILTER y l WAIN OIL FILTER Ol STOP VALVE ~ = AR/OIL UNE —= Oil UNE = AR UNE Fig 10 Discharge SystemiG! a 8.4 Cooling & Lubrication System a) b) °) Refer the figures given in the following pages The cooling and lubrication system consists of fan, shroud, oil cooler, oi fiter and thermal valve ‘The pressure in the receiver/sump causes fluid flow from sump to airend through oil cooler, thermal valve and oil filter. The thermal valve is fully closed when the oll temperature is 155 ° F. REFER PARTS LIST FOR THE TYPE OF THERMAL VALVE USED ON THE PARTICULAR MODEL. As the discharge temperature rises above 155°F due to the heat of compressor, the oil temperature rises and the thermal valve begins to close the oil line from tank to airend through oil filter to divert the oil through oil cooler. Depending on the oil temperature the thermal valve opening position ensures oll inlet temperature to airend is maintained by. Fully allowing oil from tank to airend Fully allowing oil from cooler to airend Mix of oil from tank and cooler to airend During starting of the machine the oil temperature and pressure are low. The oil separated from air/oil mixture in the receiver tank flows through the return line (Scavenge line) to the Alrend This continues till the required pressure is built up in the receiver tank. As the compressor continues to operate, the temperature of the oil also rises Once the intended pressure is built up in the receiver tank, oil starts to flow to the main line by pressure differential through the oil cooler, main oil filter, bearing oil filter atid oll stop valve to the AIREND in large quantities i.e. from the high pressure region in receiver tank to. the low pressure region in airend. The retum line is operated throughout the whole process. The radiator type air cooler removes the heat of compression from the oil Now the oil after being cooled is filtered in preparation for injection into the compression chamber and bearings of the compressor unit. The fier has a replaceable element and a built-in bypass valve which allows the oil to flow even when the filter element becomes clogged or when the viscosity of the oil is too high for adequate flow, which requires changing of fiter element. After the oil is properly filtered, it flows through the oil stop valve and to the compressor unit where it * cools the seals and the compression chamber as well as lubricating the bearings and gears. 89oe ENGINE, MAIN. OWL FILTER Fig 11 OIL STOP VALVE SIGHT GLASS BEARING OIL FILTER Cooling and Lubrication System RETURN LINE OIL RETURN LINE OIL PTRANER MINIMUM: PRESSURE VALVE ’ Breau ontcx YET VANE BALL VALVE = AR/OIL LINE —> ol UNE —= AR UNEtr LG La The cil stop valve functions on shutdown of the unit and shuts off the oil supply to the air end unit. The oil stop valve is held open by a pressure signal rom the air end during Compressor running. Atshutdown, the pressure signal is lost and the oil stop valve closes, isolating the airend from the cooling system. A portion of the oil flowing to the airend is routed to a bearing oil filter. All oil flowing to the gears, shaft seal and the internal bearings of the compressor unit flows through this extra-fine filter ensuring the cleanest possible oll for these components. This filter also has built-in bypass valve and a replaceable element. Use Elgi Air Lube Oil for the best performance of your Compressor Part No. : 000 9 98043 SPECIALLY FORMULATED MINERAL OIL FOR SCREW AIR COMPRESSORS 6118.5 Elgi Airlube Oil performs a very critical function in the oil flooded screw type air compressor. This takes away major part of the heat of the compression, seals all the areas and lubricates bearings and gears. The major criteria in a good quality lubricant for screw compressor are : a) Viscosity b) Wear characteristic cc) Demalcibility d) Heat resistance ) Thermal stability Elgi Airlube is blended using heavy-duty hydraulic based oil with proper amount of additives and strict quality control check of every batch footprint ensures satisfactory compressor performance. Life of mineral oil is covered by operating temperature for every 10° C of temperature beyond 95°C, life of oil goes down by almost 30-40%. It is recommended that oil change frequency could be vary between summer months and winter months to get best out of the mineral oil and compressor. For this, a good record of operating temperature of compressor is essential . Continuous operating of compressor at high temperature beyond 100°C without changing the oil will lead to varnish formation and will affect the life of bearings and air end THE OIL CHANGE HAS TO BE DONE FOR EVERY 500 HRS OF RUNNING . 8.12Ey Es a rt 9.0 SAFETY AND INTERLOCKING DIVICES The following safety and interlocking devices have been equipped with your ELG] PORTABLE ROTARY SCREW AIR COMPRESSOR for. safe and reliable service 9.1. Safety Devices 9.2 Presure Relief Valve is located on the wet side of the oil separator of the receiver valve tank and is set to open if the tank pressure exceeds 40 psi more than the working pressure. Discharge Temperature Switch is fitted on the panel board to shut down the compressor if the discharge air/oil mixture temperature reaches the preset value of 110 +/-5 deg C depending on probe position. The probe is fitted on air end outlet cover or receiver tank. (This feature is not available for models with Ashok Leyland Engine) Interlocking Devices The following interlocking devices have been equipped with your compressor for safe and reliable service. i Minimum Pressure Valve fitted at the outlet of the oil separator keeps minimum receiver tank ptessure of about 4 kgl/em? during all conditions which facilitates proper air-oil separation and oil circulation to air end. Oil Stop Valve located in the downstream of bearing oll filter and the upstream of air end, puts off the oil supply to the compressor unit when the unit is shut down. Pressure Regulator Valve can be varied depending upon your pressure requirements. It is set to supply the pressurized air pulse to the single acting actuator, which in turn will operate the butterfly valve to gradually open ot close the inlet port of the Air End, in accordance with the outlet air pressure An actuator connected to the butterfly valve opens the butterfly valve or closes the butterfly valve gradually in response to the pressure signal received from the pressure regulator valve thereby controlling the amount of air intake to the air end. 9.05 SS SS 10.0 10.1 10.2 ELECTRICAL SYSTEM & CONTROL ELEMENTS System Components & Description The electrical system comprises of not only necessary equipment to operate the compressor, but also a system is included to shut down the machine in the event of a malfunction. The conponents of the electrical system are an engine starter with an integral solenoid; batteries (one or two as the case may be), an alternator with built-in voltage regulator. ‘The Electrical Control System comprises of 1. 24 Volts battery 4 Ammeter 3. Alternator with built-in voltage regulator 4, Ignition / Override switch 5. Engine stop knob 6. Start push button 7. Engine starter with integral solenoid 8. Hour meter 9. Indicating lamps Instrument Panel InstrumentPanel consists of ine pressure gauge, discharge temperature gauge, engine oil temperature gauge, engine water temperature gauge, engine oil pressure gauge, ammeter, start button, override key, engine stop knob, tach-hour meter, indicating lamp The functional locations of the following controls are as follows. The Line pressure gauge is connected to the dry side of the receiver tank and continuously monitors the service line air pressure. The Discharge temperature gauge monitors the temperature of the air and oil leaving the eir end Engine oil pressure gauge monitors engine lub oll pressure Engine oil temperature gauge monitors the temperature of the engine oil inside the crank case. Engine water temperature gauge monitors the temperature of the cooling water The ammeter indicates the performance of the electrical charging system . Upon starting the engine, the needle should move to the positive (+) side of zero (0), howeve’ the needle should fall back to a position slightly past the zero on the plus side after the engine starts. The ammeter should never indicate a reading on the negative (-) side of zero as this indicates that the alternator is not charging 100Tor FUEL_ SOLENOID SEs ots 4 ot - C) > 1, 24 VOLT NEGATIVE GROUI!O SYSTEM TURN THE STARTING KEY SWITCH AMMETER 2. ee TO. START POSITION.TO CRANK cea THE ENGINE SIMULTANEOUSLY PRESS THE STARTER PUSH BUTTON. 3. RELEASE THE PUSHBUTTON AFTER ENGINE FIRES. x a fe fa fe 4, WATCH THE LUBE. QIL PRESSURE GAUGES AND SHIFT STARTING SWITCH KEY TO RUN POSITION WHEN OIL PRESSURE GAUGES: INDICATE MORE THAN TKo/Sa.cm. SWITCH ON THE TOGGLE SWITCH BEFORE ENGINE STARTS AND BATTERY 24°V D.C Fig 12 Electric Circ SWITCH IT OFF AFTER ENGINE SHUTS. DOWN, mes | TL rae] a Ete OH, a 2 177] USE FOR STARTER MOTOR - TYPE : SM 130PE Diagram for KCL Engine On 35 ROOF LAMP PUSH-PULL SWITCHES 24 VOLT NEGATIVE GROUND SUPPLY IstaEe IE a mt Engine stop knob when pulled puts off the engine Start Button : Press button to start the engine . Release immediately when engine fires. Override Key : Turn key to chieck all electrical connection. Further turn to override all switches Tach Hour Meter: This indicates the engine speed as well as the accumulated hours of compressor operation. This is useful for planning and logging service operation 10.3 Purpose Of Controls a Ot. Start push button Press to start the engine. Release fmediaely when engine fires 02. Engine stop Knob Pull the knob to stop 03. Override Key Turn key to check all electrical connection Further turn to override al switches. Release the key once engine starts 04, | Ammeter Monitors the performance of the engine alternator and is the primary indicator of an electrical malfunction. The normal reading is slightly “0” on the positive side 05. | Engine oll pressure gauge | Monitors engine oil pressure, Normal reading is 3-4 kgflcm? at rated RPM 06. Engine water temperature gauge Monitors the temperature of the engine water. Normal operating temperature is 70-90° C 07. Engine oil temperature gauge Monitors engine oil temperature. Normal operating temperature is75-95°C 08. Discharge temperature gauge Monitors temperature of air/oil mixture leaving the compressor unit Monitors oil level in the Receiver Tank. Check oil level only when 09. | Oil sight glass Olt sightigia machine is shut down. Cuts off flow of oil to the compressor unit when the machine is 40. | oi stop valve shut down and allows flow of oil to the unit on start up Maintains minimum pressure of 3-4 kgf/cm? in the receiver tank 11. | Minimum pressure valve This valve restricts receiver air discharge from receiver tank to the service line when pressure falls below 3-4 kfg/em?. However full flow is allowed at normal operating pressure. 103Control or Indicator purpose Single acting actuator Regulates the amount of air allowed to enter the inlet valve. This regulation is determined by the amount of air being used at the service line .| Pressure Regulator valve Opens a pressure line between the receiver tank and actuator allowing actuator to regulate air delivery according to air demand .| Pressure relief valve Opens when pressure in the tank exceeds the designed value 10.4ti BE Q beg 11.0 MAINTENANCE 11.1 General As you proceed in reading this Chapter, it will be easy to see that the maintenance programme of the unit is quite minimal but important. The use of the service indicator provided for the suction filter would alert you when service maintenance is required. For maintenance requirements of engine, refer to the engine manual for a detailed description of service instructions. 11.2 Daily Operation Prior to starting the machine, itis necessary to check the oil level in the receiver tank. Should the level be low, add the necessary amount. If the addition of oil beco nes too frequent, a problem has devel- oped which Is causing this excessive loss. See the trouble stiooting section under excessive coolant consumption for a probable cause and remedy. Aiter a routine’ start has been made, observe the instrument gauges and be sure they monitor the correct readings for that particular phase of operation. After the machine has warmed up it is recommeded that a general chack on the overall machine and instruments be made to assure that the compressor is running properly. r WARNING Do not remove caps, plugs or other components when compressor is running or pressurised. Stop Compressor and relieve all internal pressure before doing so. NOTE Carryout the first oil change after 100 hours of operation and subsequent oil changes after every 500 hours of operation11.4 apes 11.5 oer Maintenance After initial 100 hours of Running Alter the initial 100 hours of Operation of Compressor, some check up is needed to trace and clean the system of any foreign materials, which might have gone into it during handling/commissioning or during packaging (in case of skid models). Carryout the following maintenance operation so as to prevent the Compressor from giving trouble. Change the oil filter kit Change the Compressor oil Check fan belt tension Maintenance After every 200 Hours of Running Change the oil filter kit Check pressure relief valve Check control system Check inlet air filter Maintenance Above 500 Hours of Running Change the compressor oil for every 500 hours of running Change Air filter element for every 1000 hours of running Change Oil Filter Kit for every 500 hours of running Change Separator element after 1500 hours of running Clean water in the radiator after every 1000 hours of running After completion of 2000 hours, in additon toall above, clean the receiver tank thoroughly. Also check all the dccéssories independently for its functions and replace the components as necessary. NOTE The change hours are given as a guideline for normal operating conditions and may vary depending on site conditionsfH i Q 4 11.6 11.6.1 11.6.2 Components Maintenance & Replacement procedure Oll Filter The oil filter is incorporated in between air cooled or water couled oil cooler and the compressor unit. The oil fitter exploded view is illustrated in Figure. This is a full flow filter with a replaceable pleated element. For servicing this filter, order the repair kit. The procedure for complete service of this filter is explained below. Disassembly Disassemble the oil housing by removing the four hex bolts holding the head assembly to the main body. + Remove the O ring from the main body + Dislodge the filter element from the head assembly + Clean the head assembly and housing thoroughly Reassembly Lubricate the new O ring and re-position in main housing Replace the new filter element onto the head assembly Place the head assembly with altached filter back into housing Re-tighten the four hex bolts Seperator Element The separator element must be changed once in a year. Order separator element kit. Follow the procedure explained below for separator replacement 1. Relieve oil pressure from the receiver tank and all fluid lines 2. Disconnect all piping connecting to the receiver tank cover to isolate the receiver tank from return lines, sérvice line etc. . 3. Loosen and remove hex head bolt from the cover plate 4. Lift the cover plate from the receiver tank Remove the separator element 112FILTER HEAD ;__ BODY SEAL ELEMENT SEAL BOLT ELEMENT CH nowswe Fig 14 Oil Filter - Main BearingELGI Scrap the old gasket material from the cover and flange on the receiver tank. While doing so, care should be taken, not to let the scraps fall in the receiver tank Inspect and clean the receiver tank for rust, dirt etc. Fix the new gasket Replace the new separator element into the receiver tank taking care not to dent it against the tank ‘opening Clean the underside of the receiver tank and remove any rust Replace the cover plate and fasten the cover on the receiver tank. Reconnect all pipings. While doing so, make sure that the return line tube reaches upto a dimensional clearance of 1/4" above the bottom of the separator element. This will ensure proper oil return flow to the Compressor. ‘ Clean the return oil strainer before restarting the machine. 11.4AIR FILTER ae PRE FALT By Fig 15 Inlet Air Filterfi in Q bed 11.6.3 Air Inlet Filter When the air filter clog indicator indicates the blocked condition, remove the air filter and replace with new air filter Never Clean the Air Filter with Compressed Air 1 Place a bright light inside the element to inspect for damage or leak holes. Light rays will pass through the element where holes are present and destroy the same. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets be evident, correct the condition immediately. If the clean element is to be stored for later use, it must be stored in a clean container After the element has been installed, inspect and tighten if necessary all air inlet connections prior to resuming operation. 11.6.4 Drive Coupling Dismant! ling Whenever major repair/overhauling is carried-out on the unit, the airend should be removed, for that, follow the dismantling and assembling procedure as detailed below. 1. Unscrew the bolts on the engine flywheel Unscrew the bolts on the adaptor ring Remove airend bottom support screws Lift the airend along with the drive coupling to the work table Unscrew the bolt connecting the rubber element with the hub Using puller remove the hub from the airend shaft Clean all the components thoroughly, if any component found damaged replace it with anew on Find below the table containing tightening torque setting values for the screws used for holding the couplir No ‘Aluminium casing Locking bolt to Coupling element adopter plate Locking bolts to hub Grade 8.8 Torque Nm Grade 8.8 Torque Nm = 01 m2 70 mi6 180ee Assembling 1) Check engine crankshaft end play using dial gauge in the following manner: ) Remove the engine inspection door. Position the crankshaft at any one/end using any lever and measure the run out of the crankshaft at the fan side using dial gauge. Then move the crankshaft to the other end using the lever and measure the end play as well as the run out. 2. Measure the depth of mating face of engine housing and engine flywheel 3. Assemble the adaptor plate on the fly wheel of the engine 4. Assemble the Aluminium drive disc on the adaptor plate 5. Assemble the adaptor ring on the air end mounting face 6. Clean the hub bore and insert it on the compressor shaft using a pusher 7. Assemble the rubber element with the hub 8. Now take the airend to the engine and couple them by clamping the adaptor ring with the engine flywheel 9. Assemble all the components of the drive coupling with the required torque NOTE * Adrive coupling operating in correctly assessed system requires no maintenance. itis recommended that the rubber Element is inspected for every 5000 hours. A small amount of rubber dust is normal. In initial running large quantities of dust requires inspection . During asssembly assemble all components of drive coupling with proper torques.11.6.5 11.6.5. 11.6.5. 11.6.5. ty el LG Control System Adjustment The first step in adjustment of contro! system is adjusting control linkage between engine governor and actuator. Adjust the slider in such a way that engine reaches its full rated speed when engine is started. At full rated speed of the engine butterfly valve should be fully open or approximately 15 - 20° off of the vertical. NOTE 45 - 20 deg does not apply to inlet valve lever. Above adjustments. have been made to set control system in proper position for final adjustments 4 Operating Adjustments Start thé compressor. Allow the unit to operate until normal operating temperatures are attained. During this time, ensure service valve is fully open, Adjust tl e engine to operate at its full rated speed 2 Pressure Regulator Valve Adjustment ‘Turn the pressure regulator valve screw clockwise fo ensure it is out of adjustment. Start closing service valve slowly till ated pressure is reached. The engine should operate at rated speed with the compressor, so that a condition is obtained where the engine operates at rated speed to the rated pressure of the compressor. Tum the pressure regulator valve screw counter clockwise till actuator begins to operate. Lock the ajusting screw with lock nut. Continue Closing service valve slowly, speed of the engine reduces while butterfly valve closes to match the output. At this time pressure regulator valve setting is complete 3 Idle Speed Adjustment The last step in the capacity control adjustment is engine idle speed and compressosr butterfly valve adjustment : Continue closing the service valve, the speed of the engine will drop with constant working pressure and closing of butterfly valve to match the output of air, when engine reaches 1100 rpm adjust stop screw at the engine governor, thus preventing further drop in speed of the engine. Now close the service valve fully. Once engine is running idle at specified speed the inlet valve should be closed. Then the air pressure will stabilize at 1 kgf/cm? more than set working pressure. NOTE While adjusting capacity control system, make sure you follow the sald procedure. If you are not sure, contact nearest Elgi Equipments Branch for Help nsmen ser. Ou SPRING: Presa Ss cover SRNG READER eta Fig 16 Minimum Pressure Valve| tn S Q 11.6.6 Minimum Pressure Valve The details of minimum pressure valve inner elements are shown in Fig on Page No.11.9 Minimum pressure valve maintenance is quite minimal. The only part which normally requires replace- ment is the O ring on the piston Minimum pressure valve cover is under heavy spring tension . Loosen the cover bolts alternatively each tum to relieve spring tension. Before performing maintenance on valve, be sure that all pressure has been relieved in the machine receiver tank and all downstream pressure has been vented to the atmosphere. WARNING Extreme caution should be taken when removing the cap or cover from the body because of the spring tension. To replace the O ring follow the procedure explained below : 1. Evenly remove the cap to relieve the spring tension Remove the spring Remove the piston Remove the O ring and discard Clean the piston Replace the O ring Coat the piston and Q ring with grease Replace the piston eS PNeeZsaope Replace the spring and cap 14.10CYLINDER HEX BOLT M6X15 ) TK SD VALVE BODY ae wmock nut Ms Se? PISTON ‘oO’ RING" STEM | QUAD RING apni “OD i Fig. 17 Oil Stop Valve wlHi E @ bd 11.6.7 Oil Stop Valve The exploded view of Oil stop valve is illustrated on Fig on Page No.11.14 Using repair kit, follow the instructions given below for the proper installation, 1.» Remove the cap screw securing the cylinder to the valve body and remove the cylinder . Inspect for scratches and scoring etc. 2. Disassemble *O’ ring from the stem by removing the nylock nut on the end of the stem 3. Discard the “O” ring and nylock nut. Replace these with new ones provided in the kit. When reassembling, replace the 1/4" nylock nut also 4. Remove and replace the valve body *O’ ring . Reassemble the cylinder to the valve body 5. Remove the valve body, cap and spring, Remove the valve seat from the stem by unscrewing and teplace the same with a new one Remove and replace the gasket between the valve body cap and the valve body and also use a new spring 8 Re-assemble the spring and cap. 11.12fe Fig 18 Blow Down Valve WafH Ee Q rt 11.6.8 Blow Down Valve The exploded view of Blow down valve is illustrated on Page No. 11.13 Blow down valve maintenance is limited to replacement of the cover gasket and internal ring and seat Using repair kit, follow the instructions given below for proper installation +. Remove the four screws on the top cover which hold the assembly together 2 Pull the top cover away from the body 3. Remove the old gasket and replace with the new one. 4. Align the top cover with the body, replace the four screws and tighten, 5 Toreplace the valve seat, loosen and remove the two socket head screws in bottom cover 6. Pull the bottom cover from the main body re Remove the cover ring, spring, seat cup and seat. Discard the svat and ring, replace with the new ones in the kit. 8. Re-assemble the bottom cover. 14.44Fig 19 Discharge Check Valve 14.45;ty cr Q bed 11.6.9 Discharge Check Valve The exploded view of Discharge Check valve is illustrated on page No.14.15. To dismantle the Discharge Check Valve, follow the instructions given below 1. 2. Dismantle the flexible hose on the discharge piping between the airend and the receiver tank Dismantle the hose adapter and the reducing bush fitted on valve outlet port Unscrew the valve housing from the compressor unit The assembly now should fall away from the compressor unit Remove the three allen screws on the housing Remove the plug on the housing and loosen the fourth smaller allen screw The adapter would be separated from the housing . Check the spring and plunger for polishing or wear 7 Place the spring and plunger in position on the housing as they were prior to disassembly Replace the plug screws to secure the cover to the housing and reconnect all disconnected pipings. Replace flexible hose and start the machine to check for leaks. 1.16SPRING SEAT TOP HEX SCREW: SPRING DAMPENER ; PRESSURE PLATE NUT ROVER LOCK WASHER SPRING SEAT BOTTOM SEAT RING DIAPHRAGM DIAPHRAGM GASKET Bopy SEATGASKET ’ Fig 20 Prassure Regulator WaTi Ec Q bed 11.6.10 Pressure Regulator Valve The exploded view of Pressure Regulator is illustrated on Page No.11.17 Pressure regulator valve maintenance requires replacement of the diaphragm. Only use repair kit and follow the procedure given below for proper installation. 1 Loosen the lock nut and turn the adjusting bolt counter clockwise until the inner spring tension is relieved. The adjusting screw should turn freely when the spring tension is relieved, Remove the top housing from the bottom housing to allow access to internal parts. Next remove the spring button and the spring . Loosen the pressure plate nut on the top seat to replace the diaphragm available in the repair kit. 11.18END COVER ‘O° RING. CYUNDER BODY SPRING. “THREADED BUSH LOCK NUT BUSH PLUNGER ROD PLUNGER HEX.BOLT-MBxX30 (CUP SEAL, SPRING WASHER-MA HEX.NUT-MB Fig 21. Single Acting Actuator 11911.6.17 Single Acting Actuator The section view of Actuator is shown on Page No. 11.19 The Single Acting Actuator requires a maintenance check once in every 6 months or 1500 hours of operation whichever is earlier. During this check, replacement of components is not necessary if they are in good condition. Thorough cleaning and lubricating the moving components would be sufficient. But once in a year all the sealing components and the spring have to be replaced The procedure is given below 1. Unscrew the bolts and nuts and then remove the end cover and ‘O° Ring 2. Remove the plunger along with the plunger rod 3. Check the cup seal. Change if it is found damaged 4, Remove the spring and check the stiffness 5. Replace worn out / damaged components before assembling NOTE During replacement, compulsorily all the components should be thoroughly cleaned and lubricated 11.20' 12. TROUBLE SHOOTING 42.1. Engine not starting | No fuel Check fuel level and add fuel if necessary | Clogged fuel filter : Replace the element Low battery voltage Check electrolyte level and add water and recharge if necessary Loose battery cables Tighten cables Dirty battery cables Clean thoroughly Clogged air filter Clean or replace the element Engine problems may have Refer to your Engine Manufacturer developed Defective engine oil pressure Replace the defective switch switch, compressor discharge temperature switch BISWA TBs Check electrical continuity and replace if necessary No fuel Check fuel level and add fuel if necessary 12.2 Machine shuts down with air demand present Compressor discharge tempera- ture switch is open a) Cooling ait flow is insufficient Clean cooler and check for proper ventilation b) Low oil level in receiver tank Add oil ©) Dirty oil Change oil d) Clogged oil filter Change oii fiter elements Defective discharge temperature Check for a short or open circuit to the fuel| switch solenoid should this check out normal, it) would be possible that the temperature| switch itsedf is defective. 120Engine water temperature switch is open a) Cooling air flow restricted Clean the radiator core b) Low water level + Fill the radiator with adequate water ©) Defective switch Replace ) Blown fuse in wiring hamess Check continuity and replace if necessary 12.3. No building of Line pressure Air demand too great Check service lines for leaks or open valves Dirty air filter Pressure regulator valve out of adjustment Check the filter indicator and change or clean element if required Adjust pressure regulator valve accord- ing to control adjustment instruction in che maintenance section Defective pressure regulator Defective minimum pressure valve Check diaphragms and replace if necessary Check and ensure piston is moving freely 12.4 Improper unloading with an excessive pressure build up causing pressure relief valve to open Pressure regulating valve is set too~ high Re-adjust Leak in the control system causing loss of pressure signal Check control lines Defective diaphragms in the actuator Replace diaphragms (kit avaitable) Defective pressure regulator valve Inlet valve jammed. Repair the valve (Kit available) Repair / replace the valve Restriction in the control systems Check all control lines and components and remove the foreign particles clogging the system Jammed control linkage Clogged air/oil separator element Free the jammed portion of the link- age and adjust if necessary. Replace separator element 12.5 Insufficient air delivery Clogged air filter Clean or replace the element Replace separator element and also change the compressor oil and oil 121Problem Causes Clogged air/oil separator filter at this time Faulty pressure regulator Adjust or repair Engine speed too low Clogged return line Re-ad/ust engine speed Clean oil return strainer and orifice 12.6 Excessive compressor oil consumption Defective blow down valve Leak in the lubrication system Replace diaphragm Check all pipe connections components and 12.7 Compressor overheating Separator element damaged or not functioning property Change separator element Excessive oil in the Receiver Tank Loose or broken fan belt Drain to corfect level Tighten or change belt Dirty oi cooler core Clogged oil cooler tubes (internally & extemally) Low receiver tank oil level Clean core thoroughly Clean tubes thoroiighly Fill up to max. level Clogged oil filter Clean or change the main oil filter and bearing oil filter. Clogged oil return line Clean oil return strainer and orifice Wrong grade of cil Drain and flush the system thoroughly. Use recommended grade of oil 12.8 Engine overheating Loose or broken fan belt Tighten or change belt Dirty radiator core Clean thoroughly Faulty engine thermostats Replace thermostats Clogged radiator Clean thoroughly Low oil level Refill Other engine problems Refer to engine manual 12.9 Back flow of oil through Check oil stop valve, service if necessary Check discharge check valve 122INSPECTION AND SERVICE RECORD Results of Inspection and Outline of Service ate of Scheduled Inspected Date of t | Date of Next ; - Delivery Pipe, inspected or Inspection Compnlellon Inspection and |. Oll | Fiston Ring Nave Pipe Seat Gihers Serviced by of Service Sandee) Exchange li ‘Air Tank —+—— +ELGi 13. RECOMMENDED SPARES 13.1 Kit of Spares For DZ 23 036 / DU 23 040 Models Kit of spares after completing 2500 hours K 03 23 011 of running contains 2. Kit, Air filter 23.04 1949 9 2 sets 3. Kit, Main oil filter 01 14 09769 14 sets 4, Kit, Bearing oil fitter 01 140975 9 7 sets 5, Seprator element 22 03 2260 B 2Nos 6. Hose, Flexible 2 1/2" 22.08 2209 B 1 No 7. Gasket for Hose, flexible 22 04 7539 B 2 Nos 8 _ Kit, Valve, Minimum pressure 2 ¥," NPT 22.02 1861 9 1 set 9.__ Kit, Valve, Discharge check 2 ¥," NPT 22.03 11539 1 set 10. Kit, Valve, Oil stop valve 2" NPT 22.03 1032 9 1 sat 71. Kit Actuator, single acting 22.02 7190 9 + set 12. Kit valve, pressure regulator - 1 1/4°NPT 22 03 1759 9 1 set 13. Kit, Valve, Blow Down 1 '/," NPT 22 03 2288 9 1 set 14. Kit, Valve, Pressure Relief 1," NPT 22.02 7277 9 1 set 48. Element coupling, TDS/27, 03.04.4915 0 2 Nos For DZ 23 044 Model +. Kit of spares alter completing 2500 hours of running contains K 03.23 01 2. Kit, Airfilter. - - 2304 19499 4 sets 3. Kit, Main oil filter 01 1409769 14 sets 4. Kit, Bearing oil filter 01 14 0975 9 7 sets 5. Seprator element : 22 03 2250 B 2 Nos 6. Hose, Flexible 2 1/2" 22 03 2209 B 1 No 7. Gasket for Hose, flexible 22 04 7539 8 2 Nos 8 Kit, Valve, Minimum pressure 2 1," NPT 22 02 1561 9 4 set 9. Kit, Valve, Discharge check 2 '/," NPT 22.03 11539 1 set Vaive, Oil stop vaive 2° NPT 22 03 1082 9 T set 11. Kit Actuator, single acting 22.02 71909 T set 12. Kit valve, pressure regulator - 1 1/4°NPT 22.03 1759 9 set 18. Kit, Vaive, Blow Down 1 ¥," NPT 22 03 2208 9 {set 14. Kit, Valve, Pressure Reliet 1 ¥," NPT ~~ 22:02 72779 {set 18. Element coupling, TDS /27 03 04 4915 0 2 Nos 13.0For DY 23 044 Model K 03 23 013 1. Kit of spares after completing 2500 hours of running’ contains e 2. Kit, Air filter 01 14 09779 2 sets “3. Kit, Main oil filter 01 1409769 14 sets 4. Kit, Bearing oil filter 01 14.0975 9 7 sets 5. Seprator element 22.03 2259 B 2 Nos 6. Hose, Flexible 2 1/2" 22 03 2299 B 1.No 7. Gasket for Hose, flexible 22 04 7539 B 2Nos 8. Kit, Valve, Minimum pressure 2 '/," NPT 22.02 1561 9 1 set 9. Kit, Valve, Discharge check 2 ¥/," NPT 22 03 1153 9 1 set 10 Kit, Valve, Oil stop valve 2" NPT 22.03 1032 9 1 set “11. Kit Actuator, single acting 22.02.7190 9 1 set 12. Kitvalve, pressure regulator - 1 1/4"NPT 2203 17599 : 1 set 13.. Kit, Valve, Blow Down 14 ue NPT - 22 03 2288 9 1 set 14. Kit, Valve, Pressure Relief 1 ee NPT 22°02 7277 9 1 set 15. Element coupling, TDS / 27 03 04 4915 0 2.Nos Use Elgi Air Lube Oil for the best performance of your Compressor Part No. : C00 9 9804 3 SPECIALLY FORMULATED MINERAL OIL FOR SCREW AIR COMPRESSORS 13.4ELGI FACTORIES, BRANCH & FOREIGN OFFICES ee CORPORATE REGISTERED OFFICE ee, ELGI EQUIPMENTS LIMITEL Trichy Road, Singanallur, COIMBATORE - 641 008. India, 91-422] 2574691 [2573697 [into@elgicoin FACTORIES SINGANALLUR | Trichy Road, Singanallur, COIMBATORE - 641 005. India. | 91-422 | 2574691 [2573697 into@elgiccoin KURICHY Private Industrial Estate, Kurichy, Coimbatore - 641 021. India, | 91-422 | 2672201-3|2675446 | aed@elgi.co.in TRAINING CENTRE India House, Trichy Road, COIMBATORE - 641 018. India. 91-422 | 2302106-8} 2302111 | trgcentre@elgi.co.in BRANCH OFFICES AHMEDABAD “ELGI HOUSE" 2, Mill Officer's Colony, 91-79 26583736 | 26587683 | elgiahmedabad Behind La-Gajjar Chambers, (Old Reserve Bank), Opp. Times 26581274 @elgi.co.in of India, Ashram Road, AHMEDABAD - 380 009. India. BANGALORE 15,16 Richmond Road, BANGALORE - 560 025. India 91-80 22240674 | 2293274 | elgibangalore@ 22220296 elgi.co.in 22122479 BHOPAL M-1, “Purjor House”, Block No. 32, Indira Press Complex, | 91-755 | 2578281 | 2578289 | elgibhopal@ Zone 1, M.P. Nagar, BHOPAL - 462 011, Madhya Pradesh. 2578317 elgi.co.in 5273317 2552159 CHENNAI 52, Second floor, “Amar Sindhur 43, Pantheon Road, 91-44 28586699 | 28586499 | elgichennai Egmore, CHENNAI - 600 008. India. 28513599 @elgi.co.in 28555199 28553599 COIMBATORE ELG! Equipments: Limited, Coimbatore Branch, 91-422 | 2574691 | 2573697 | elgicoimbatoret Trichy Road, singanallur, Coimbatore - 641 005. Extn,223 elgi.co.in HYDERABAD 1-8-6114, Airport Plaza, 3rd Floor B, Opp. Airport, 1-40 | 27768326 | 27768327 | elgihyderabad Begumpet Road, HYDERABAD - 500 016. India. 27768226 @elgi.co.in JAIPUR T-13, 3rd Floor, Jeevan Vihar, 4 New Colony, jayanthi Market. | 91-141 | 2375595 | 2377100 | elgijaipur@ JAIPUR - 302 001. India, elgi.coin KOCHI XXXIX/3873, P.O.Box No.1884, M.G Road, ERNAKULAM, 91-484 | 2360155 | 2351904 | elgikochi@ KOCHIN - 682 016. India. elgi.co.in KOLKATA MW Floor, Parijat Building, 244 Shakespeare Sarant, 91-33 22834270 | 22834272 | elgikolkatta@ KOLKATA - 700 017. India. 22834271 elgi.co.in MUNBAL Marcol Co-op Industrial Estate Ltd, Plot No. 48, 91-22 28591905 | 28591601 | elgimumbai@ J.B. Nagar Post, Mathuradas Vassanji Road, Andheri (East), 28591906 elgi.co.in MUMBAI - 400 059. India. 28501682 ‘NEW DELHI 23, Shivaji Marg, NEW DELHI - 110 015. India. ot-tt 25437593 | 25459375 | elgidelhi@ 25153644 elgi.co.in 25175029 25175018 PUNE White House, 2nd Fioor, 388-A, 1/2240, Mumbai Pure Road, | 91-20 27145288 | 27145289 | elgioune@ (Opp. Sandvik (Asia), Dapodi, Pune - 411 002. India 27148892 elgi.co.in TIRUCHENCODE| 4/2, Nandhini Complex, 1st Floor, Sadyian Street, 91-4288) 257137 257693 eigitirucheng Vellore Road, Tiruchencode - 637 211. India. elgi.co.in FOREIGN OFFICES BANGLADESH | ELGI Equipments Limited, C/o. FAD Enterprises Limited, 200 | so71450-s7 [2-0516149 | iacatabecom Sonartori Tower (15th & 16th Floor), No. 12, Biponon C/A Sonargaon Road, Dhaka - 1000, Bangladesh ‘SRILANKA ELGI Equipments Limited, 17/17, Wijayba Road, 494-4 811848 74300362 | elgi@dynanet.1 Off-Nawala Road, Nugegoda, Colombo INDONESIA ELGI Equipments Limited, C/o. P.T. Abdi Sejahtera, JI. Pemuda | 021 4722160 4705982 tksuryap@yahe fo. 66, Ground floor, Rawamangun, Jakarta 13220 Indonesia UAE ELGI Equipments Limited, G/o.Tech Internationa varia | 2694909 [2611073 | eigi@emiates P.0.Box : 3390, Dubai. Mab(971) THAILAND ELG! Equipments Limited, C/o. PP. Paris Co. Ltd., 112/5-6, Mahasap | 662 5192611 5102785, jimppparts@ Gondiown, Hunancian Road, Klangkum Bungkum, Bangkok 10240 yahoo.com nem nmin Aan) SV a SN SHEER) SESE eesEee SAAR RAE