R E C I P R O C A T I N G

A I R C O M P R E S S O R
FOR SHUNTING LOCOMOTIVE/DMU

2 STAGE 2 CYLINDER
TRC 2507

OPERATION AND MAINTENANCE

M A N U A L / P A R T S L I S T

Fab. No........................................
ELGI EQUIPMENTS LIMITED
Coimbatore - 641 005, INDIA.

Doc No :- 07 90 04 010
Revision :- R 01

Revision status
R00 - First Edition : October 2000
R00 - Second Edition : July 2003
R01 - First Revision : Nov 2011

PRICE : INR. 500.00

Compiled by

Engineering Department

Approved & Issued by

Research & Development Department

List of contents

I. List of contents .......................................................................................................................................... III

II. Machine Identification and Sale record ............................................................................................... V

III Message from the Managing Director .................................................................................................. VI

IV About Elgi ................................................................................................................................................. VII

V. Instruction ................................................................................................................................................ VIII

VI. User's Commitment ................................................................................................................................. IX

VII. Notes & Warnings .................................................................................................................................... X

VIII. Using this Operation & Maintntenance manual ................................................................................. XI

IX. Customer Care System (CCS) ............................................................................................................. XII

X. Do's and Dont's .......................................................................................................................................... 1

XI. Safety Instruction ..................................................................................................................................... 2

1. Technical Data ............................................................................................................................................. 5

2. Recommended Lubricant / Manufacturer ................................................................................................. 6

3. System Operation ........................................................................................................................................ 6

4. Function of Various System ........................................................................................................................ 7

5. Safety And Interlocking Devices ................................................................................................................ 8

6. Instalation ..................................................................................................................................................... 9

7. Operation ................................................................................................................................................... 11

8. Maintenance ............................................................................................................................................. 13

9. Trouble Shooting ...................................................................................................................................... 20

10. Recommended Spares ............................................................................................................................ 22

11-1. Reciprocating Air Compressor Unit Package ........................................................................................ 27

11-2. Piston Assembly, Dia 197 ........................................................................................................................ 33

11-3. Piston Assembly, Dia 127 ........................................................................................................................ 33

11-4. Valve Assembly, Breather ........................................................................................................................ 33

11-5. Valve Assembly, Drain ............................................................................................................................. 33

11-6. Valve Assembly, Inlet ............................................................................................................................... 35

11-7. Valve Assembly, Discharge ..................................................................................................................... 35

11-8. Valve Assembly, Suction Unloader ......................................................................................................... 37

11-9. Air Intake Strainer With Mounting Flange .............................................................................................. 37

12. Notes .......................................................................................................................................................... 38

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Machine Identification and Sale Record

Owner’s Name : .............................................................................................

Address : .................................................................................................

.............................................................................................

.............................................................................................

Model : .................................................................................................

FAB. No. : .................................................................................................

Year of manufacturing : .................................................................................................

Motor : ............................................................................................ kw

Capacity : ......................................................................................m 3 /min

Rated Pressure : ..................................................................................... bar g

Date of Delivery : .................................................................................................

Date of Commissioning : .................................................................................................

-v-
Message from the Managing Director

Dear ELGI customer,

It gives me great pleasure to welcome you to the family of users of Horizon compressors from
ELGI, among the most sophisticated rotary screw air compressor available in the world today

ELGI has designed your Horizon compressor to be reliable, safe, easy to maintain andf r i e n d l y
to use in meeting your compressor air requirements. This user manual will enable you to
use the Horizon compressor optimally. please familiarise yourself with all the information it Contains.

I look forward to your continued satisfaction as a Horizon user. ELGI honoured to be your choice
for all your compressed air needs

Yours sincerely,

Jairam Varadaraj

Managing Director

- vi -
About ELGI

Elgi’s experience in the design and manufacture of air compressors spans 50 years.
Established in india in 1960 as a reciprocating air compressor manufacturing company, ELGI
gained its reputation for design and manufacture of screw compressors through strategic partnership
and continuous research and development. Over the years, it emerged as a multi-product multi-
market enterprise providing total compressor air solutions in all segments. Elgi’s design capabilities
translated into wide range of products ranging from oil-lubricated and oil-free rotary screw
compressor, oil-free reciprocating compressors and centrifugal compressors.

Screw compressor elements are manufactured in-house using state-of-the-art machining centres
for rotor grinding and machining intrinsic castings of various sizes. Elgi own V(eta V) profile rotors
ensure energy-effficient compressed air supply for all demanding applications. Elgi is one of the
few companies capable of manufacturing wide range of airends and compressor packages in the
world.

Elgi has modern manufacturing facilities in india, China and France. It’s equipped with state-of-
the-art high precision rotor cutting and grinding machines, turning centres, CNC horizontal and
vertical machining centres.

All manufactured components / products pass through stringent quality audits and are tested to
ensure performance and reliability. Our Manufacturing test rooms are atmospheric controlled. All
parts and finished products undergo stringent quality checks to ensure that Elgi delivers only high
quality products to its customers.

Over two million compressors are powering business in 63 countries worldwide. The company
offers a strong sales and service network of 14 domesticc and 6 overseas offices, besides a well-
knit distribution network of 114 dealers in india and 165 distributors worldwide. Elgi has set up
warehouse facilities in Brazil and Middle East.

Driven by the philosophy of Think Long Run, ELGI believes in forging long running partnerships
with its stakeholders worldwide guided by reliability, technology, capability, and values fuelled by
innovation.

-vii-
Introduction

We are confident; the equipment you have purchased will give you satisfactory service for its life.
We thank you for giving us an opportunity to serve you with our compressor

Please check and ensure OPERATION AND MAINTENANCE MANUAL AND PARTS MANUAL
are present when receiving the compressor. This operation and maintenance manual has been
specially designed keeping you in mind, so that you can get the most out of ELGI compressor.
Before you start using your compressor, do go through this manual thoroughly. It contains vital
information on operation and useful tips that will keep your compressor running as good as New
Year after year.

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

This manual must be made available to the compressor operating personnel at all times. Please
read the instructions very carefully, right to the end, as the operating life and reliability of the
compressor depends to a large extent on correct operation and maintenance

- viii -
User's Commitment

Read and understand all of the operating instructions, safety precaution and warnings in the
instruction manual before operating or maintaining this compressor.

Most accidents that result from compressor operation and maintenance are caused by the failure
to observe basic safety rules or precautions. An accident can often be avoided by recognizing a
potentially hazardous situation before it occurs, and by observing appropriate safety procedures.

Basic safety precautions are outlined in the “SAFETY” section of this instruction manual to be
followed with atmost care to be taken throughout the life of the equipment.

Never use this compressor in a manner that has not been specifically recommended by
manufacturer, unless you first confirm that the planned use will be safe for you and others.

Attend to any signs of minor irregularities immediately. If neglected, they could become worse.

Ensure the operation instruction manual be made available to the compressor operating personnel
at all time

Ensure the use of Genuine ELGI spares and while ordering spare parts, the following particulars
must be clearly mentioned to ensure supply of the right spares.

1. MODEL

2. FAB NUMBER

3. YEAR OF MANUFACTURE

4. PART NAME

5. PART NUMBER

6. REQUIRED QUANTITY

- ix -
Notes and Warnings

In case of any requirements of spares or service, please contact our nearest branch office
or distributors

Due to improvements being made constantly and continuously, the illustrations and
descriptions on this manual are not binding

SAFETY

IMPORTANT SAFETY INSTRUCTIONS FOR USE OF THE COMPRESSOR

WARNING
Death or serious bodily injury could result from
improper or unsafe use of compressor. To avoid these
risks, follow the basic safety instructions.

NOTE
Make sure this manual is read and carefully understood
before starting/operating this machine.

Proof of purchase will be required for warranty service.

-x-
Using this Operation and Maintenance Manual

This operation and maintenance manual has been specially designed keeping you in mind so
that you can get the most out of your customize ELGI compressor. Before you start using
your compressor, go through this manual thoroughly. It contains vital information on operation
as well as useful tips that will help you keep your compressor running as good as New Year
after year.

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

All the information, illustrations and specifications in this manual are based on the latest
product information at the time of preparation of the manual. We reserve the right to make
changes in the product at any time without notice.

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

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Customer Care System (CCS)

Customer Care systems (ccs)

ELGI provides dedicated customer care and after-sales support through the CCS, a
computerised system developed in-house. The CCS aims to minimize the time taken to
resolve complaints.

Service Requests / Complaints

At the heart of the CCS is the toll- free telephone number 1800-425-3544 (within india BSNL
MTNL lines) at the centralized customer care centre in Coimbatore. Customers can register
their service requirements or complaints with coordinators here.

A unique tracking number is generated for each call logged by the CCS. The customer is
sent an automatic e-mail acknowledgement with the tracking number and details of the call
for references.

A service engineer is assigned to the call, and the date and time of the engineer’s visit are
communicated to the customer by e-mail. Every requirement / complaint must be resolved
and closed in the CCS within a specified time limit, failing which the call is brought
automatically to the notice of the manager higher in the hierarchy, upto the level of the
Managing Director. Thus the CCS ensures that not only are customer complaints logged,
they are also attended on time every time.

Enquiries

A number of calls received by the CCS related to customer’ queries regarding products and
spare parts. The details are noted and basic information on product specifications and usage
are provided. The caller is informed whom to contact for further discussions. The enquiry is
passed on to a sales person at the head Office or the appropriate branch for follow-up.

The CCS Database

The CCS also creates a database of customers, adding every new customer calling and
thereby building a large pool of installation details. These details are used to provide value -
added services to improve customer satisfaction with ELGI products

CCS - Working Hours

Customers can now use the CCS from 08:30 to 21:30 IST six days a week (Monday to
Saturday). ELGI has received suggestions that the service be extended to Sundays.

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Customer Care System (CCS)

Multi-lingual Capability

The co-ordinators at the CCS are Multi-lingual. They can handle calls in all the major regional
languages of India

Coverage
The toll-free number of the CCS is accessible from the following areas.

Southern Region : Tamilnadu, Karnataka, Kerala, Pondicherry, Adhra Pradesh,

Andaman & Nicobar Islands
Western Region : Maharashtra, Gujarat, Madhyd Pradeh, Goa,
Lakshadweep Islands
Eastern Region : Orissa, Chattisgarh, Jharkhand, West Bengal, Bihar and the
North-Eastern states
Northern Region : Rajasthan, Uttar Pradesh, Delhi, Hariyana, Punjab,
Uttaranchal, Himachal and jammu Kashmir

Other ontact Number :

The CCS can also be availbled through the follwing numbers.
Telephone : 0422-2589206 / 2589241 / 2589242 / 2589243 2589244 /
2589245 / 97900 21100
Fax : 0422-2589240

E-mail : ccs@elgi.com

Customer Satisfaction survey :

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

- xiii -
Do's and Don'ts

DO

✓ Read the manual in detail and follow the Instructions.

✓ Clean the air compressor package regularly.

✓ Keep the air filter clean.

✓ Use only genuine spares.

✓ Maintain correct oil level.

✓ Use only clean, recommended lubricants.

✓ Use proper tools.

✓ Attend immediately to anything unusual with the air compressor.

✓ Maintain Log Book to monitor opeation of compressor.

✓ Attend Repairs / Service with qualified technicians only.

DON'T

✗ 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.

✗ Run the compressor without fan guard.

✗ Use cleaning agents, when changing oil.

✗ Do any repair work while the unit is running.

✗ Overload the compressor for long period, although it is of continuous rating.

-1-
Safety Instructions

Never touch moving parts

Never place your hands, fingers or other parts near the compressor’s moving parts

Never operate without all guards in place

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

Always wear eye protection

Always wear safety goggles or equivalent eye protection. Compressed air must never be
aimed at anyone or any part of the body.

Protect yourself against hot spot

Prevent body contact with grounded surfaces such as pipes, cylinders, cylinder heads and
motor. Never operate the compressor in damp or wet locations.

Disconnect the compressor

Always disconnect the compressor from the power source and remove the compressed air
from the air tank before servicing, inspecting, maintaining, cleaning, replacing or checking
any parts.

Avoid unintentional starting

Do not carry the compressor while it is connected to its power source or when the air tank is
filled with compressed air

Store compressor properly

When not in use, the compressor should be stored in dry place, remove the electrical supply.
Keep out of reaach of children. Lock-out storage area.

Keep work area clean

Cluttered areas invite injures. Clear all works areas of unnecessary tools, debris, furniture etc.

Keep children away

Do not let visitors contact compressor extension cord. All visitors should be kept safely
away from work area.

Operate compressor at the rate voltage

Operate the compressor at voltages specified on the nameplates. If using the compressor at
a higher voltage than the rated voltage, it will result in abnormally fast motor revolution and
may damage the unit and burn out the motor

-2 -
Safety Instructions

Never use a compressor which is defective or operating abnormally

If the compressor appears to be operating unusually, making strange noises or otherwise

appears defective. stop using it immediately and arrange for repairs by a authorized service
center.

Use only genuine replacement parts

Replacement parts not original may void your warranty and can leads to malfunction and
result injuries. Genuine parts re available from your dealer.

Do not modify the compressor

Do not modify the compressor. Always contact the authorized service center for any repairs,
Unauthorized modification may not only impair the compressor performance but may also
result in accident or injury to repair personnel who do not have the required knowledge and
technical expertise to perform the repair operations correctly.

Turn off the starter stop button to be latched when the compressor is not used

When the compressor is not used, Disconnect it from the power source and open the drain
cock to discharge the compressed air from the air tank.

Dress properly

Not wear loose clothing or jewellery. They can be caught in moving parts. wear protective
hair covering to contain long hair.

Maintain compressor with care

Follow instruction for lubricating. Inspect cords periodically and if damaged, have repaired
by authorize service facility. Inspect extension cords periodically and replace if damaged.

Check damaged parts and air leak

Before further use of the compressor, in guard or other parts is damaged should be carefully
checked to determine that it will operate properly and perform its intended function.

Check for alignment of moving parts, binding of moving parts breakage of parts, mounting,
air leak and any other conditions that may affect its operation.

A guard or other parts that is damaged should be properly repaired or replaced by an authorized
service centre unless otherwise indicated elsewhere in this Instruction Manual. Have defective
pressure switches replaced by authorized service centre. Do not use compressor if switch
does not turn it on and off.

-3 -
Safety Instructions

Handle compressor correctly

Operate the compressor according to the instructions provided herein. Never allow the
compressor to be operated by children, individuals unfamiliar with its operator or unauthorized
personnel.

Keep all screws, bolts and cover tightly in place

Keep all screws, bolts and plates tightly mounted. Electrical connections to be ensured for
tightness. Check their conditions periodically.

Keep motor air vent clean

The motor air vent must be kept clean so that air can freely flow at all times. Check for dust
build-up frequently.

Drain Tank

Drain tank daily or after 4 hours of use. Open drain fitting and tilt compressor to empty
accumulated water.

Electrical installation

This compressor motor and starter should properly grounded with correct size copper wire to
avoid electrical shock and damage to the equipment.

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

The correct rating of wires to be used for incoming connection and length of the cable to be
less than 5 mtrs.

never take any loop lines from the compressor wiring.

WARNING
Avoid electrical shock hazard. Never use this
compressor with a damaged or frayed electrical cord
or extension cord. Inspect all electrical cords regularly.
Never use in near water or in any enviornment where
electric shock is possible.

-4 -
1. TECHNICAL DATA

01 Model TRC 2507

02 Type Reciprocating, Air cooled, Splash

lubricated

03 Displacement M3/min 3.292

cfm 116.252

lpm 3292

04 Free air delivery M3/min 2.600

cfm 91.818

lpm 2600

05 Working pressure kgf/cm2 7

06 Type of configuration V

07 Compression Stage No. 2

08 Cylinders No. 2

09 Cylinder size & stroke mm 197 x 127 x 90

10 Type of piston rings Dia 197 Dia 127

a) Plain compression No. 1 1

b) Stepped compression No. 1 1

c) Slotted oil control No. 2 2

11 Type of valve Individual disc valves LP & HP

(Suction & Delivery)

12 Volumetric Efficiency % 79

13 Compressor speed rpm 1200

14 Type of lubrication Splash

15 Type of cooling Air

16 Type of fan Forced draught

17 Oil fill capacity ml Max. 3000, Min. 2500

18 Grade of oil Servo Press 150

19 Direction of rotation viewed Clockwise-Viewed for from non-

from non-driving end drive end Standard Model

Counterclockwise-Viewed from
non-drive end Cummins Model

-5-
 20 Safety valve set pressure - kgf/cm2 5
Intercooler
21 Overall dimensions L x B x H mm 820 x 670 x 855
22 Net Weight kg 650
23 Mounting hole L x B 200 x 480
24 No. of holes 4 holes, dia 17
25 DRIVE
a) Type of drive V belt
b) Type of groove C
c) No. of groove No. 2
d) Compressor pulley, OD mm 460.4
e) Compressor pulley, PCD mm 449

2. RECOMMENDED LUBRICANT / MANUFACTURER

Recommended Oil

Ambient ISO Bharat Indian Oil Chemoleums Bharat Shell

Temp0C VG No. Petroleum
25 to 80 ISO 150 Bharat Servo Press Erato Shell
Compressor 150 150 HDC Corena
Oil 50 P 150

3. SYSTEM OPERATION

3.1. The atmospheric air aspirated through the inlet air filters is compressed in the low
pressure cylinders of the reciprocating air compresor driven by the prime mover.

3.2. Under normal condition, the first stage compression end temperature amounts to
approximately 195 0 C. This compressed air enters into the inter cooler. Where the
compression heat is considerably reduced. Inter cooler has safety valve which opens
when the compressed air pressure exceeds the pre-determined set pressure.
Intercooler also houses a drain valve, used to drain the accumulated moisture after
shutdown of the machine.

3.3. This cooled compressed air then enters into the high pressure cylinder, there it is
further compressed to attain the specified pressure. The discharge side of high
pressure cylinder head is connected to an outlet flange from which the compressed
air is drawn out for service.

3.4. The suction unloaders provided on the suction valves of each cylinder head control
the loading and unloading of the compressor in accordance with the air pressure in
the reservoir.

-6-
4. FUNCTION OF VARIOUS SYSTEM

4.1 Reciprocating Air Compressor Unit

The Reciprocating air compressor unit consists of 2 sets of cylinders and cylinder
heads - one for first stage (low pressure) and one for second stage (high pressure)
fitted in 'V' configuration on a crankcase. Concentric type individual disc valves
areprovided on cylinder heads to perform air suction and discharge operations. Also
suction unloaders are fitted on the suction valves for automatic suction unloading and
loading with respect to air pressure in the air reservoir.

The reciprocating compressor unit converts the rotary motion into reciprocating motion
with the help of crankshaft and connecting rod assembly. Due to the reciprocating
motion, the air is sucked into the cylinder, compressed and the compressed air is
delivered into the service. The concentric type disc valves perform the suction and
discharge operations.

The crank case is made of high grade cast iron and houses the crankshaft assembly. It
acts as the sump for the lubricating oil and is provided with an oil level indicator, a
drain plug and a breather. The breather maintains a partial vacuum inside the crank
case to facilitate proper lubrication.

The crankshaft and connecting rod assembly is precision machined and dynamically
balanced. Double row heavy duty ball bearings are provided on both the ends of the
crankshaft assembly. Connecting rod big end is provided with cylindrical steel roller
and small end is provided with phosphor bronze bush bearing. The crankwebs are forged
out of carbon steel, case hardened and precision ground. The crankshaft assembly is
provided with an oil splasher for lubricating all moving parts by splashing the oil in the
crankcase.

The pistons fitted to the connecting rods are of automotive type and are of low expansion
aluminimum alloy. The pistons are provided with plain, stepped compression and slotted
oil control rings. The rings are made of special quality close gained pearlitic cast iron
and designed for controlling wear and oil consumption to a great extent. The gudgeon
pins are of chromium steel case hardened and precision ground.

The cylinders and cylinder heads have deep fins for effective cooling and are made of
high grade cast iron to ensure high wear resistance. The cylinders bores are precision
honed. Air passages of the cylinder heads are generously curved for easy air flow.

An inlet air filter is fitted to suction port of LP cylinder head. This efficient dry type air
filter is used to eliminate the dust particles in the suction air. This ensures maximum
life for the cylinders and pistorns.

-7-
 The intercooler is radiator type consisting. No. of finned tubes arranged parallely,
connecting the first stage discharge and the second stage suction and is provided
with a drain valve and a safety valve set to open if the pressure in the intercooler
exceeds the limit mentioned in the technical data. The spindle of the safety valve
can be lifted manually is required.

4.2. Drive System

The drive system, transmits the power required to drive the compressor from the
prime mover. The drive system comprises of a drive pulley mounted on the
locomotive shaft and a driven pulley mounted on the crank shaft of the compressor
unit. The motion is transmitted between the pulleys through ‘V’ belts. The pulleys
have ‘C’ type groove construction.

The dynamically balanced driven pulley, fitted on the crankshaft acts as a fly wheel
which imparts vibration free dynamic rotation of the crankshaft. The fan fitted on
the driven pulley forces the air on the cylinders, cylinder heads and inter cooler
which cools down the temperature of whole unit.

5. SAFETY AND INTERLOCKING DEVICES

This category comprises of Safety Valve (Intercooler) and Suction unloader valve.

5.1. Safety Valve Intercooler

Vents excess air pressure to atmosphere in the intercooler when the pressure inside
inter cooler rises above 130% of intermediate pressure.

5.2. Suction Unloader Valve

A suction unloader valve each is fitted on the suction valve of each cylinder head.
When the air pressure in the reservoir exceeds the pre-determined value, the suction
unloader valves actuate and compress the inlet valve plats and keep them open
continously till in the air pressure comes down in the reservior. Under this condition,
no air compression takes place and hence the locomotive receives very less load
due to compressor unloading operation.

-8-
6. I N S TA L AT I O N

l Examine the package for transit damages,

l Leave 1000 mm space around the compressor for adequate cooling and
easy maintenance accessibility.

6.1. Location of Compressor

The compressor package may be placed on any levelled surface capable of supporting its
weight. It is necessary to anchor the unit as there is a possibility of applied forces or
vibration which could disturb the piping.

6.2. Ventilation and Cooling

Select a location to permit sufficient unobstructed air flow in and out of the compressor
room to keep the operating temperature stable. The minimum distance that the machine
hould be from surrounding walls is within working limits. The machine should be
installed at a minimum of 1000 mm from the surrounding walls. It is imperative to
provide adequate cross ventilation to precent excessive ambient temperature rise.

6.3. Oil Level Check

Pour proper quantity of oil and check the oil level during installation. The level is checked
by looking at the dipstick provided on the crank case. If the oil level is low, add sufficient
quantity of oil up to maximum level marked on the dipstick.

Oil fill capacity : Min. 2500 ml

Max. 3000 ml

Before starting the units, fill the crank case with correct grade and proper
quantity of oil since oil is drained completely prior to shipping.

l Fill the lubricating oil into the crank case through breather hole after
removing the breather from the end cover.

-9-
 6.4. Belt Tension

Ensure proper belt tension between the drive pulley (engine pulley) and driven pulley
(Compressor pulley). When correctly adjusted, the belt should have a ply of 10 mm
about their mean position.

Too much belt tension will lead to excessive load on the Compressor and Engine
bearing.

6.5. Direction of the Compressor

After the unit installation, it is necessary to check the direction of the compressor
rotation. Start the unit momentarily and observe the direction of rotation of the
compressor. The direction of rotation should be as per Specification (See Technical Data)

- 10 -
7. O P E R AT I O N

7.1. General

While ELGI has built into this compressor a comprehensive array of controls and
indicators to assure you that it is operating to full capability, you will want to recognize
and interpret the reading which will call for service or indicate the beginning of a
malfunction. Before starting your Elgi compressor, read this section thoroughly and
familiarize yourself with the controls and indicators - their purpose, location and use.

7.2. Purpose of Control

CONTROL OR INDICATOR PURPOSE

1. Pressure gauge Continously monitors air receiver / delivery

pipe presure at a various load and unload
conditions

2. Dipstick Helps to keep a visual check on the oil level

in the crackcase. Check oil level only when
the machine is shut down. Do not over fill.

3. Safety valve-Intercooler Set to open intercooler air pressure to

atmosphere if pressure - exceeds 130% of the
intermediate pressure of the compressor.

4. Suction unloader valve Unloads the air from the suction port when
the air pressure in the reservoir exceeds the
pre-determined valve and loads the
compressor when the pressure drop down in
the reservoir without stopping the
compressor.

5. Breather Maintains partial vaccum inside the

crankcase to facilitate better lubrication.

6. Drain valve Used to drain the condensate in the

intercooler.

7.3. Intial start-up Procedure

l Read the preceeding pages thoroughly

l Ensure all preparations and checks described in the chapter installation have
been taken care of.

l Fill the recommended grade of oil in the crankcase to the required level.

l Recommended Oil is servo press 150 or equivalent

- 11 -
l Ensure proper belt tension. Too much tension will induce an excessive load on
engine and compressor bearings.

l Check that the compressor rotates freely by handle and there are no mechancial
obstructions.

l Check that the drain on the intercooler is closed.

l Run the compressor for a while and close the shut off valve. Then carry out a check
on all parameters and function of accessorries used in compressor.

l Check for possible leaks in piping.

l Re-inspect the machine for temperature and leaks the following day.

7.4. Checks During Compressor Operation

l Check whether the compressor is running smoothly and that the running sound is
normal.

l The compressor crankcase shall be hand-felt to ensure that its temperature is within
touchable limit through out the duration of operation of compressor.

Do not touch the delivery parts of the compressor since they are very hot.
Touching may cause burns.

l Observe for air leaks at the joints of the pipes and if noticed, stop the compressor and
rectify the defects.

7.5. Subsequent Start Up Procedure

On subsequent start up check the proper oil level is visible in the dipstick and simply
start the engine.

To shut off the machine stop the engine.

- 12-
8. MAINTENANCE
8.1 General
Follow the maintenance schedule described in this chapter for excellent trouble free
services.
FREQUENCY MAINTENENCE REQUIRED CLAUSE No.

Every 15 days Check oil level 8.2

Check belt tension
Drain Condensate from intercooler
Every 30 days Observe noise and vibration 8.3
Check fasteners
Check oil level
Check leakage at the shaft seal
Check and clean berather valve
Check inlet air filter
Every 3 months Change oil 8.4
Check belt tension
Drain Condensate from intercooler
Observe noise and vibration
Check fastners
Check leakage at the shaft seal
Check and clean breather valve
Check inlet air filter
Decarbonise all disc valves
Recondition all suction unloaders
Check tightness of compressor pulley locknuts
Every Half Yearly Decarbonise all disc valves
Check tightness of compressor pulley locknuts 8.5
clean coolers
Every one Year Overhaul compressor 8.6
Change inlet air filter element

As you proceed in reading this chapter, it will be easy to see that the maintenance
programme of the unit is quite minimial but important.

Cleanliness and care must be observed whenever lnspection and checkes are being
carried on the compressor its accessories. For cleaning interior parts, only rags which
do not separate should be used. Cotton waste should not be used. If any defect is
noticed it should be maintained attended to. The unit should be properly maintained as
per the undermentioned scehdule.

l Lubricating oil change should be carried out during every 30 days or

500 hours Schedule
l Recommended lubricating oil, Servo Press 150 of IOC make
or equivalent.

- 13 -
8.2. During Every fifteen days

l Check the compressor thoroughly.

l Check the oil level in the crank case. Replenish with the correct grade of oil if
required.

l Check the belt tension

l Drain the intercooler in order to remove the moisture collected in it. Run the
compressor for a few minutes with drain valve open so that the moisture will be
removed completely.

8.3. During Every thirty days

Check the compressor for satisfactory operation which include

l Cleanliness of the compressor

l Operational noise and vibration

l Tightness of mounting bolts and other fasteners

l Oil level in the crankcase. Replenish with the correct grade of oil if required.

l Oil leaks at the shaft seal.

l Breather valve should be dismantled cleaned and checked for perfect seating of
the valve.

l Clean the suction filter thoroughly.

8.4. During Every three months

l All check points indicated under 30 days schedule to be carried out

l Check the safety valve setting

l Dismantle the disc valves, check the spring plate and valve palate. There
should not be scratches and damages in the seating of the valve plates. If there
is any damage it should be replaced. If the springs are damaged, replace them.
All the parts should be dismantled and cleaned thoroughly in kerosene. Reassmeble
the valve and assemble it to the cylinder head.

l Check the tightness of the compressor pulley on the compressor shaft.

l Change the oil

- 14 -
8.5. During Every Half Yearly

l All check points indicated under 30 days schedule to be carried out

l Dismantle the disc valves check the spring plates and valve plate. All the parts
should be decarbonised and cleaned thoroughly in kerosene. Reassemble the
valve and assemble it to the cylinder head.

l Check the tightness of the compressor pulley on the compressor shaft.

l Clean the intercooler and decarbonise.

8.6. During Yearly

l A general overhaul should be done. The compressor should be completely stripped

by experienced staff. All parts should be thoroughly cleaned, examined and
repaired in a clean surrounding.

l Check the crankshaft and connecting rod assembly thoroughly. There should not
be any shake in the connecting rod about the crank pin. This can be checked by
fixing the crankshaft assembly between centres and shaking the connecting rod.
Also check the small end needle roller bearings. If there is any major repair, the
same may be attended to immediately.

l Replace a set of belts eventhough a belt is not found worn out.

- 15 -
8.7. Components Maintenance and Replacement Procedure
8.7.1. Intercooler

Loosen simultaneously the hexagon nuts of intercooler flange

Pull out the intercooler inspect the gasket and renew them if damaged.

Decarbonize and clean the intercooler thoroughly

While assembling tighten the hexagon nuts simultaneously.

8.7.2. Cylinder Head and Valve System (LP and HP)

Remove the pressure pipe line connection from the suction unloader valve assembly.

Unscrew and remove the cap nut and the suction unloader valve body.

Unscrew the suction valve plug using a special tool meant for unscrewing it.

Take out the suction valve from the cylinder head

Remove the discharge valve cap nut and valve plug

Take out the discharge valve. Take care not to damage the copper packing rings.

Dismantle the valves, clean all the components thorough in kerosene and inspect the
valve plates and the springs

If any component found damaged, replace it with a new one.

Check the springs stiffness and if necessary replace them.

The valve seats may be lapped if necessary

Before assembling, ensure that all the mating faces are in good condition.

8.7.3. Cylinder

Loosen all the nuts of the cylinder and slowly pull out the cylinder with both hands. If
it is tightly fixed on the crankcase, rotate the compressor pulley and the cylinder will
automatically come up.

Take out the cylinder, examine its bore for scratched and other damages.Measure the
cylinder bore, if the limiting size (given in table 01) has been exceeded, replace the
cylinder and piston assembly.

- 16 -
8.7.4. Piston Assembly

Remove the circlip using a circlip plier and then gently knock out the gudgeon pin.

Inspect for scratches (change pin) or slackness of the pin in the piston boss (change
piston)Remove the piston rings using the piston ring expander.

Decarbonize and clean the piston and ring grooves thoroughly.

Inspect the piston for scoring and other damages and replace it if necessary.

Reassemble the ring in piston and measure the side play. Place the ring in the cylinder
bore, seat it perfectly and measure the butt clearance. Replace the rings as a set when
limiting clearances/play have been reached or if any one of the rings is broken.

Permissible clearances/play, refer Tab. 01.

NORMAL MAXIMUM
COMPONENT SIZE IN MM CLEARANCE CLEARANCE
IN MM PERMISSIBLE
IN MM

Low Pressure
piston and rings

Piston diameter 196.62 to 0.18 to 0.26 0.40

at skirt 196.67

Piston ring butt - 0.20 to 0.45 0.55

Clearence

Piston ring side 0.05 to 0.10 0.15

Play in groove -

Cylinder 196.85 - -
Dia 197 196.86

High pressure
piston and rings - - -

Piston diameter 126.79 to 126.82 0.17 to 0.20 0.30

at skirt

Piston ring 0.10 to 0.35 0.45

butt clearence -

Piston ring side

play in groove - 0.03 to 0.085 0.10

Cylinder 126.99 - -
Dia 127 127.00

Table 01 Permissible clearance / Play of piston assembly.

N ormal clearnace in cylinder between piston crown and cylinder top should be 0.6 to 0.8 mm

- 17 -
8.7.5. Crankshaft and Connecting Rod Assembly

After removing the piston inspect the crankshaft and connecting rod assembly.

Check whether it has any shake or whether the bearings are worn out.

Worn out or damaged crankshaft and connecting rod assembly can be reconditioned
only by the manufacturer since it requires specil fixtures and precision equipment
for dismantling and assembling.

For removing the assembly from the crankcase, follow the dismantling procedure
described below.

Remove the breather assembly from the crankcase. Use a puller to pull out the
compressor pulley without damaging the fan blades and 'V' grooves.

Remove the end cover fixing bolts of both free and flywheel ends.

Remove the free and cover and then remove the crankshaft assembly along with
the fly end cover, through the opening of the crankcase at the fly end.

Remove the fly end cover, inspect the oil seal, distance bush and the bearings. If
they are damaged, replace with new ones.

If replacement of crankshaft and connecting rod assembly is not necessary, clean

the assembly thoroughly with kerosene and dry compressed air before
reassembling.

8.7.6. Bearings
Remove the bearings from the crankshaft using a bearing puller. Do not hammer
the bearing races.

Clean the bearings thoroughly using diesel and inspect them

If they are in good condition, oil them and keep them free from dust. Do not keep
the bearings dry.

In order to assemble the bearings on the crankshaft, heat them by flame or using
hot plate or in an oil bath to a temperature from 100 0 C to 120 0C.

8.7.7. Safety Valve

Loosen the lock nut and unscrew the pressure adjuster from the safety valve
housing.

The actuating rod along with the valve cone, valve seat and spring can then be
removed from the safety valve housing.

Check the seat in the housing carefully and ensure that the same is not damaged
prior to reassembling

-18 -
 The spring should also be checked for stiffness, if it has lost its characteristics replace
it by a new one.

If any parts are damaged, replace them with new ones, prior to reassembling.

While setting the safety valve, ensure that it opens at the desired pressure. For
setting,follow the procedure given below.

Tighten the pressure adjuster to an extent where the safety valve opens at the desired
pressure setting. Tighten lock nut after the desired setting has been attained.

Check operation of the new setting of the safety valve for a few times.

8.7.8.Breather Valve Assembly

Unscrew breather valve assembly from end cover of the crank case.

Dismantle breather valve assembly by removing counter sunk screws.

Clean and check diaphragm, breather top and breather bottom.

Replace diaphragm if necessary.

Re-assemble breather valve and refit on end cover of crank case.

8.7. 9. Drain Valve Assembly

Unscrew drain valve assembly from air receiver / intercooler

Dismantle drain valve assembly

Clean and check all the components

Replace valve seat and cone seat if necessary

Re-assemble drain valve assembly and refit.

- 19 -
9. TROUBLE SHOOTING

DEFECTS LIKELY CAUSES REMEDIES

Compressor Overheats Dirty Oil Change Oil

Oil level low Fill correct grade of oil upto
maximum level
Cylinder and intercooler Blow with compressed
fins dirty air or clean manually
Breather value Open clean and refit after
not working checking.
Compressor does Blocked unloader pipes Open and clean
not unload Defective suction unloader Remove, dismantle the
suction unloader, clean and
refit.
Oil carry over in Chocked air filter Clean on renew the air
compresed air filter element.
Oil level high Drain to correct level
Oil viscosity too low Change to / recommend
grade
Breather not working Open, clean and refit
after checking.
Piston rings stuck in Loosen the piston rings.
grooves or broken If broken, change the ring
as a set. Check all related
parts for wear before fitting.
Piston to cylinder Check and change
Clearance excessive as required
Usual wear of cylinder, Inadequate air filter Increase frequency
piston and piston rings maintenance as required
Oil change frequency Increase frequency
insufficient with more periodic check of
oil.
Incorrect grade of oil Change in correct grade as
given in recommended
lubricants charts
Water or rust formation in Faulty breather Check and replace the
crankcase. breather valve. if necessary.

- 20 -
 DEFECTS LIKELY CAUSES
Oil leak through breather Breather valve is not
value working
Piston rings stuck in
grooves or broken.
Piston to cylinder clearance
excessive
Abnormal noise and Loose compressor pulley
compressor knocking
Worn out piston, cylinder,
crankshaft and connecting
rod bearings
Pressure built up time Loose belts
excessive
Leaky joints in pressure lines
Defective seating of inlet and
delivery valve plates
Worn out piston rings
Excessive belt wear Incorrect engine and
compressor pulley alignment
Incorrect belt tension
Compressor package Uneven surface level
vibration
Mounting bolts and nuts
loose
- 21 -
REMEDIES
Open, clean and refit the
breather.
Loosen the piston rings. If
broken, change the rings as
a set. Check all related
parts for wear before fitting.
Check and change as
required.
Remove compressor pulley
and examine keyway and
key forwear. Change the
key / pulley as required
Overhaul compressor unit.
Replace the related
components
Adjust or replace, if
elongated
Open and re-tighten with
teflon tape or jute and
shellac
Open clean and refit after
careful check.
Replace after checking the
related components.
Check and adjust using a
straight edge or string
across the diameter of both
the pulleys.
Check belt adjustment
frequently.
Check the surface with sprit
level and correct the
surface level
Tighten bolts and nuts.
10. R E C O M M E N D E D
S P A R E S

No. DESCRIPTION QTY DRAWING No.

10-1 Kit, Spare Parts, Air Compressor Unit

Model TRC 2507, 1 year 1 07 24 0339 9

1.1 Kit, Piston rings, dia 197 1 02 24 0107 9

Each kit consists of

a) Ring, plain compression, dia 197 1 00 03 2145 A

b) Ring, stepped compression, dia 197 1 00 04 4590 B

c) Ring, slotted oil control, dia 197 2 00 03 2091 A

1.2 Kit, Piston rings, dia 127 1 07 24 0347 9

Each kit consists of

a) Ring, plain compression, dia 127 1 00 04 2863 A

b) Ring, stepped compression, dia 127 1 00 04 6925 A

c) Ring, slotted oil control, dia 127 2 00 03 1666 A

1.3 Inlet Valve Assembly 3 A 07 0072

1.4 Discharge Valve Assembly 3 A 07 0071

1.5 Kit, Gasket and Sealing Parts 1 07 24 0341 9

Each kit consists of

a) Gasket, free end cover 1 00 04 4557 0

b) Gasket, fly end cover 1 00 04 4588 0

c) Gasket, crank case to dia 197 cylinder, 0.8 mm 1 00 04 4560 0

Cont...

- 22 -
 No. DESCRIPTION QTY DRAWING No.

d) Gasket, crank case to dia 197 cylinder, 0.4 mm 1 00 04 4560 A

e) Gasket, crank case to dia 127 cylinder, 0.75 mm 1 00 04 2843 A

f) Gasket, crank case to dia 127 cylinder, 0.2 mm 1 00 04 2843 B

g) Gasket, crank case to dia 127 cylinder, 0.4 mm 1 00 04 2843 C

h) Gasket, dia 197 cylinder to cylinder head 1 00 04 4561 0

i) Washer, copper Inlet & Discharge valve assembly 6 00 04 3926 0

j) Gasket, cylinder head to cap nut 3 00 04 7364 0

k) Gasket, 127 cylinder to cylinder head 1 00 04 4068 0

l) Gasket 197, cylinder head to Inter cooler 3 00 04 4573 0

m) Gasket, dia 127 cylinder head to Damp Pipe 1 00 04 4533 0

n) Ring, packing, drain plug 1 00 05 2196 0

o) Ring, packing, disptick 2 00 04 7475 0

p) Felt, packing, air intake strainer element 2 00 03 2552

1.6 Diaphragm, breather 1 00 05 1006 0

1.7 Seal, oil B50 x 72 x 12 1 00 04 2036 0

1.8 Filter Element 1 00 03 2552 0

1.9 Unloader Valve 3 A 07 0073

PS : The above spare parts are recommended for 1 year normal operation of the compressor.

- 23 -
P A R T S L I S T

- 24 -
- 25 -
 B + 10
L + 10

885+10

- 26 -
Model TPL No. L B
TRC 2507
Standard S07007 670 820
TRC 2507 S07050 650 775
Cummins
- 27-
Fig. 1 Reciprocating Air Compressor Unit Package
Model : TRC 2507
11-1 Reciprocating Air Compressor Unit Package

Fig. No. Description Qty. ELGI Part No.

1 RAC Unit Package TRC 2507 Standard S07 007
RAC Unit Package TRC 2507 Cummins S07 050
1- 1 Crankcase 1 07 02 0013 0
- 2 Stud M16 x 60 - Crankcase and cylinders 8 00 04 6530 0
- 3 a) Connecting rod and crankshaft assembly with bearing 1 07 03 0114 0
b) Connecting rod and crankshaft assembly without bearing 1 A07 0006
- 4 Ring, spacer - bearing 4 00 04 7128 0
- 5 Bearing, ball, single row SKF 6310 4 00 09 03 361
- 6 Gasket - Free end cover 1 00 04 4557 0
- 7 Cover, free end 1 00 03 2917 0
- 8 Seal, oil B50 x 72 x 12 1 00 04 2036 0
- 9 Gasket - Fly end cover 1 00 04 4588 0
- 10 Cover, fly end 1 00 03 2915 0
- 11 Washer, spring M12 16 00 09 96 112
- 12 Bolt, hex, M12 x 40 16 00 09 06 185
- 13 Piston assembly dia 197 1 00 04 4585 0
- 14 Gasket - Crankcase to dia 197 cylinder 0.75 mm 1 00 04 4560 0
Gasket - Crankcase to dia 197 cylinder 0.4mm 1 00 04 4560 A
- 15 Cylinder dia 197 1 00 03 2092 0
- 16 Washer, spring, M16 4 00 09 96 116
- 17 Nut, hex, M16 4 00 09 48 016
- 18 Piston assembly dia 127 1 00 04 2890 0
- 19 Gasket crankcase to dia 127 cylinder 0.75 mm 1 00 04 2843 A
Gasket crankcase to dia 127 cylinder 0.4 mm 1 00 04 2843 B
Gasket crankcase to dia 127 cylinder 0.2 mm 1 00 04 2843 C
- 20 Cylinder dia 127 1 00 02 1467 0
- 21 Washer, spring, M16 4 00 09 96 116
- 22 Nut, hex, M16 4 00 09 48 016
- 23 Gasket, dia 197 Cylinder to cylinder head 1 00 04 4561 0
- 24 Head, dia 197 cylinder 1 00 02 1610 0
- 25 Washer, spring, M16 6 00 09 96 116
- 26 Bolt, hex, M16 X 110, dia 197 cylinder head 6 00 09 06 226
- 27 Gasket, dia 127 cylinder to cylinder head 1 00 04 4068 0
- 28 Head, dia 127 cylinder 1 00 02 1515 0
- 29 Washer, spring, M12 6 00 09 96 112
- 30 Bolt, hex, M12 x 110 dia 127 cylinder head 6 00 09 06 197
- 31 Washer, copper - Inlet and discharge valve 6 00 04 3926 0
- 32 Valve assembly, inlet 3 A07 0072
*- 33 Valve assembly, discharge 3 A07 0071
- 34 Plug, inlet valve 3 00 03 1929 0
*- 35 Plug, discharge valve 3 00 03 1930 0
- 36 Washer, copper cylinder head to cap nut 3 00 04 3927 0
- 37 Valve assembly, suction unloader 3 A07 0073

- 28 -
- 28-
Fig. 1 Reciprocating Air Compressor Unit Package
Model : TRC 2507
 Fig. No. Description Qty. ELGI Part No.
- 38 Nut, cap 3 00 04 3928 0
- 39 Nipple hex 1" x 1" BSP 1 00 04 3209 A
- 40 Elbow 1" BSP 1 00 09 7205 5
- 41 Pipe 1" BSP breather 1 00 04 3846 0
- 42 Socket 1" BSP 1 02 04 8492 0
- 43 Valve assembly, breather 1 A02 0030
- 44 Ring, packing, drain plug 1 00 05 2196 0
- 45 Plug assembly, drain 1/2" BSP 1 A 02 0034
- 46 Ring, packing, dipstick 1 00 04 7475 0
- 47 Dipstick with chain 1 07 04 0073 0
* - 48 Gasket, dia 197 cylinder head to suction bend 1 00 04 4573 0
- 49 Bend, suction 1 00 03 2079 0
- 50 Washer, spring, 1/2" 4 00 09 9620 5
- 51 Bolt, hex, 1/2" UNC x 1 ¼" 4 00 09 0724 7
- 52 Gasket, Air intake strainer to dia 197 cyl. head 1 00 04 4573 0
- 53 Strainer with mounting flange, air intake 1 00 03 3088 0
- 54 Washer, spring, M10 4 00 09 9611 0
* - 55 Bolt, hex, M10 x 45 4 00 09 0614 8
- 56 Nut, hex, M10 4 00 09 4801 0
- 57 Gasket, dia 197 cylinder head to IC 1 00 04 4573 0
* - 58 Gasket, dia 127 cylinder head Damp pipe 1 00 04 4533 0
- 59 a) Intercooler Assembly, TRC 2507 Standard 1 00 02 1613 0
b) Intercooler Assembly, TRC 2507 Cummins 1 07 02 0017 0
- 60 Washer, spring, 1/2" 4 00 09 9620 5
- 61 Bolt, hex, 1/2" UNC x 1 ¼" 4 00 09 0724 7
* - 62 Washer, spring, M10 4 00 09 9611 0
* - 63 Bolt, hex, M10 x 40 4 00 09 0614 7
- 64 Plug 3/4" BSP - inter cooler 1 00 05 1074 A
- 65 Valve assembly, safety 3/4" BSP 1 B 84 1701
- 66 Valve assembly, drain 1/4" BSP 1 A 02 0045
- 67 Key - Word Ruff 1 07 04 0179 0
- a) Cooling fan and pully assy, TRC 2507 Standard 1 A07 0077
- b) Cooling fan and pully assy, TRC 2507 Cummins 1 A07 0539
- 68 Pulley, Compressor 1 -
- 69 Fan, cooling 1 -
- 70 Washer, spring, M8 9 -
- 71 Bolt, hex, M8 x 12 9 -
- 72 Washer 1 07 04 0015 0
- 73 Nut, castle M16 x 1.5 1 07 04 0009 0
- 74 Pin, split 1/4" 1 00 09 6549 8
- 75 Elbow 1/4" BSP 1 22 04 7681 B
- 76 'T' Branch 1/4" BSP 2 22 04 7682 A
- 77 Pipe assembly No.1, Pressure line 1 07 04 0734 0
- 78 Pipe assembly No, 2, Pressure line 1 07 04 0735 0
* - 79 Gasket, dia 127 cyl. head flange to del. manifold 1 00 04 4533 0

- 30-
- 28-
Fig. 1 Reciprocating Air Compressor Unit Package
Model : TRC 2507
 Fig. No. Description Qty. ELGI Part No.

- 80 Manifold, delivery 1 00 03 3066 0

- 81 Washer, spring M10 4 00 09 96 110
- 82 Bolt, hex, M10 x 40 4 00 09 06 147
- 83 Plate dummy, delivery flange 1 00 04 7129 0
- 84 Gasket, Dia 127 cylinder head todelivery flange 1 00 04 4533 0
- 85 Flange with pipe, delivery 1 07 04 0077 0
- 86 Washer, spring M10 4 00 09 96 110
- 87 Bolt, hex, M10 x 45 4 00 09 06 148
- 88 Nut, hex, M10 4 00 09 48 010
* - 89 Bed, unit 1 00 04 7130 0
* - 90 Plate, base 1 07 04 0072 0

* Not shown in the drawing

- 32 -
FIG. 2 PISTON ASSEMBLY DIA 197 FIG. 3 PISTON ASSEMBLY DIA 127

FIG. 4 BREATHER ASSEMBLY FIG. 5 DRAIN VALVE ASSEMBLY 1/4” BSP

- 33 -
11-2 Piston Assembly , Dia 197
Fig. No. Description Qty ELGI Part No.
2 Piston Assembly, dia 197 1 00 04 4585 0
* 2- 1 Ring, plain compression 1 -
* 2 Ring, stepped compression 1 -
* 3 Ring, oil control 2 -
* Piston with gudegon pin (incl.No 4 to 5) 1 00 04 7782 0
* 4 Piston dia 197 1 -
* 5 Gudgeon pin 1 00 04 3940 0
* 6 Circlip, internal dia 30 2 -00 09 1723 0
Kit Piston Ring ( consist of item 1,2,3 ) 1 02 24 0107 9

11- 3 Piston Assembly , Dia 127

Fig. No. Description Qty ELGI Part No.
3 Piston Assembly, dia 127 1 00 04 2890 0
* 3 - 1 Ring, plain compression 1 -
* 2 Ring, stepped compression 1 -
* 3 Ring, oil control 2 -
* Piston with gudegon pin (incl. No 4 to 5) 1 00 04 7778 0
4 Piston dia 127 1 -
* 5 Gudgeon pin 1 00 04 2864 0
* 6 Circlip, internal dia 30 2 -9 17
Kit Piston Ring dia 127 (Consists of item 1,2,3) 07 24 0347 9

11- 4 Valve Assembly, Breather

Fig. No. Description Qty ELGI Part No.
4 Valve Assembly, Breather (00 04 1138 0) 1 A02 0030
* 4 - 1 Bottom, breather 1 -
2 Diaphragm 1 00 05 1006 0
* 3 Top, breather 1 -
4 Screw,slotted head M6 x 10 2 00 05 2069 0

11-5 Valve Assembly, Drain

Fig. No. Description Qty ELGI Part No.

5 Valve Assembly, Drain, 1/4" BSP 1 A02 0045
(00 05 1541 0)
* 5 - 1 Housing 1 -
2 Cone seat 1 -
* 3 Valve seat 1 -
* Items shall be supplied as an assy only

- 34 -
 FIG. 6 VALVE ASSEMBLY INLET

FIG. 7 VALVE ASSEMBLY DISCHARGE

- 35-
11-6 Valve Assembly, Inlet

Fig. No. Description Qty Elgi Part No.

6 Valve assembly inlet 1 A 07 0072
6 - 1 Buffer plate 1 07 04 0929 0
2 Guide Plate 1 07 04 0028 0
3 Spring plate 1 07 03 0023 0
4 Valve plate 1 07 03 0029 0
5 Seat valve 1 07 04 0024 0
6 Lock nut M8 1 07 04 0930 0
7 Spring 1 07 04 0035 0
8 Bush 1 07 04 0033 0
9 Unloader 1 07 04 0034 0
10 Lock nut 1 07 04 0931 0
Kit Inlet valve assy, (Consist of items 3,4,6,10) 07 24 0372 9

11-7 Valve Assembly, Discharge

Pos Description Qty Elgi Part No.
7 Valve assy. discharge 1 A 07 0071
7 - 1 Seat valve 1 07 04 0934 0
2 Guide Plate 1 07 04 0028 0
3 Valve plate 1 07 03 0029 0
4 Spring plate 3 07 03 0023 0
5 Buffer plate 1 07 04 0935 0
6 Washer 1 07 04 0936 0
7 Lock nut M8 1 07 04 0930 0
Kit Dischargevalve assy, (Consist of items 3,4,7) 07 24 0373 9

- 36-
 FIG. 8 VALVE ASSEMBLY SUCTION UNLOADER

1 2 3 2 4 5 6 7

FIG. 9 AIR INTAKE STRAINER WITH MOUNTING FLANGE

- 37-
11-8 Valve Assembly, Suction Unloader
Fig. No. Description Qty/Unit ELGI Part No.

8 Suction Unloader Assy., (070300470) 1 A070073

8 -1 Spring Unloader Valve 1 07 04 0236 0

*2 Seat Unloader 1 07 04 0234 0

*3 Body Unloader Bushed Assembly 1 07 04 0228 0

4 'O' Ring 1 07 04 0232 0

5 Unloader Valve 1 07 04 0231 0

*6 Retainer Screen 1 07 04 0230 0

*7 Screen 1 07 04 0229 0

-8 Washer Copper 1 07 04 0233 0

-9 Nut Cap 1 07 04 0235 0

11-9 Air Intake Strainer With Mounting Flange

Fig. No. Description Qty/Unit ELGI Part No.

9 Air intake strainer with mounting flange 1 00 03 3088 0
* 9- 1 Clamp with mounting flange 1 -
* 2 Felt packing 2 00 04 6876 0
3 Element, Air intake strainer 1 00 03 2552 0
* 4 Shell 1 -
* 5 Cover Top 1 -
6 Washer Spring 3/8’’ 1 00 09 90 203
7 Nut Lock 3/8’’ UNC 2 00 09 48 603

* Marked Items are not for spare

- 38-
12. N O T E S

- 39 -