Do’s and Dont’s

Dos

3 Read the manual in detail and follow the instructions.

3 Clean the air compressor package regularly.

3 Keep the air filter clean.

3 Use only genuine spares.

3 Maintain correct oil level.

3 Use only clean, recommended lubricants.

3 Use proper tools.

3 Drain the condensate daily by opening the drain valve.

3 Attend immediately to anything unusual with the air compressor.

3 Maintain log book to monitor operation of compressor.

3 Attend Repairs / Service with qualified technicians only.

Dont’s

7 Neglect the routine attention.

7 Allow any leakage in the system.

7 Keep any tools or loose items on the compressor/other modules.

7 Meddle with any adjustments or settings.

7 Run the compressor without fan guard.

7 Use cleaning agents, when changing oil.

7 Do any repair work while the unit is running.

7 Overload the compressor for a long period eventhough it is of

continuous rating.

Downloaded from www.Manualslib.com manuals search engine

 Safety instructions

Never touch moving parts

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

Never operate without all guards in place

Never operate this compressor without all guards or safety features in place
and in proper working order. If maintenance or servicing requires the re-
moval 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, cyl-
inder heads and motor. Never operate the compressor in damp or wet loca-
tions.

Disconnect the compressor

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

Avoid unintentional starting

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

when the air tank is filled with compressed air.

Store compressor properly

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

Keep work area clean

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

Keep children away

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

Downloaded from www.Manualslib.com manuals search engine

 Safety instructions

Operate compressor at the rated voltage

Operate the compressor at voltages specified on their nameplates. If using

the compressor at a higher voltage than the rated voltage, it will result in
abnormally fast motor revolution and may damage the unit and burn out
the motor.

Never use a compressor which is defective or

operating abnormally

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

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

Use only genuine replacement parts

Replacement parts not original may void your warranty and can lead to
malfunction and resulting injuries. Genuine parts are available from your
dealer.

Do not modify the compressor

Do not modify the compressor. Always contact the authorized service

center for any repairs. Unauthorized modification may not only impair the
compressor performance but may also result in accident or injury to repair
personnel who do not have the required knowledge and technical exper-
tise to perform the repair operations correctly.

Turn off the starter stop button to be latched

when the compressor is not used

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

Drain tank

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

Dress properly
Do not wear loose clothing or jewellery. They can be caught in moving
parts. Wear protective hair covering to contain long hair.

Maintain compressor with care

Follow instructions for lubricating. Inspect cords periodically and if

damaged, have repaired by authorized service facility. Inspect extension cords
periodically and replace if damaged.

Downloaded from www.Manualslib.com manuals search engine

 Safety instructions

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

should be carefully checked to determine that it will operate properly and
perform its intended function.

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

parts, mounting, air leak, and any other conditions that may affect its
operation.

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

replaced by an authorized service centre unless otherwise indicated
elsewhere in this Instruction Manual. Have defective pressure switches
replaced by authorized service centre. Do not use compressor if switch
does not turn it on and off.

Handle compressor correctly

Operate the compressor according to the instructions provided herein.

Never allow the compressor to be operated by children, individuals
unfamiliar with its operator or unauthorized personnel.

Keep all screws, bolts and cover tightly in place

Keep all screws, bolts and plates tightly mounted. Electrical

connections to be ensured for tightness. Check their conditions
periodically.

Keep motor air vent clean

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

Electrical installation

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

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

Starter

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

Never take any loop lines from the compressor wiring.

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

Downloaded from www.Manualslib.com manuals search engine

 Technical Specifications

01 Model TRC 1000 MN UG

02 Type Reciprocating, Air cooled, ‘W’ type

and oil Splash lubricated

03 Working pressure kgf/cm 2 10.5

3
04 Displacement m /h 78.48

cfm 46.19

lpm 1308

05 Free air delivery m3 /h 60.00

cfm 35.32

lpm 1000

06 Cylinder size & stroke

length mm 100 x 60 x 100 : 85mm

07 No. of stages No. 2

08 Compressor speed rpm 980

09 Type of valve Disc valve

10 Direction of rotation Anticlockwise as viewed

from non-driving end
11 Type of drive Directly coupled with
motor by disc coupling
12 Crankcase oil capacity ml Min. 650
Max. 1880
13 Recommended oil Servo press 150
14 Nett weight kg 450±10
15 Overall dimensions mm 1135 x 770 x 925
LxBxH
16 Safety valve on intercooler
Opening pressure kg/cm2 6

Downloaded from www.Manualslib.com manuals search engine

 Technical Specifications

17 Coupling Unit

Model Disc type coupling

18 Suction filter
a. Type Dry type
19 Motor Make
a. Make CROMPTON / BHARAT BIJILI

b. Type TEFC, Sqiurrel cage

induction
c. Power HP 14
d. Voltage Base voltage 415V
(290-500v)
e. Rated current Amp 24
f. No. of phases Three phase conn. in star
g. Frequency Hz 50
h. Enclosure IP 54
g. Insulation Class H
h. Speed rpm 975 / 970
i. Rating Continuous
j. Frame Size 180L / 180 L
k. Recommended grease Lithium base GR.3
SERVOGEM GR.3
L. Weight kg 200 / 205

20 Shaft & Bore size Unit

+0.018
a. Motor shaft mm Ø 48 +0.002
+0.021
b. Coupling bore(motor side) mm Ø 48 +0.000
-0.005
c. Fan flange bore mm Ø 48 -0.016
-0.03
d.Compressor shaft mm Ø 43 -0.04
-0.030
e. Coupling bore(Comp.side) mm Ø 43 -0.050

f. Bore finish Ground

Downloaded from www.Manualslib.com manuals search engine

 Technical Specifications

Cylinder, Piston and Piston ring size

SI.No Description LP HP
+0.01 +0.01
0.00
1 Cylinder bore mm Dia 100 Dia 60 0.00
Dia 99.835 - Dia 59.941 -
2 Piston mm Dia 99.855 Dia 59.915
0.000 0.000
3 Gudgeon pin size Dia 20-0.005 Dia 18 -0.005

4 Clearance in cylinder Normal mm 0.15 - 0.16 0.06 - 0.09

Max mm 0.25 0.20

5 No. of plain compression rings 1 --

6 No. of stepped compression rings 2 --

7 No. of slotted oil control rings 2 --

8 No. of perma seal ring -- 2

9 No. of oil control three piece ring -- 2

10 Permissible piston rings ,

Permissible stepped rings ,
Permissible oil control rings ,
butt clearence Normal mm 0.08 to 0.25 --
Max. mm 0.40 --

11 Permisible perma seal piston ring butt

clearance 0.06 0.09

Permisible perma seal oil control ring

clearance 0.25 --

12 permissible piston rings side

play in groove Normal mm 0.04 to 0.08 0.024 to 0.074
Max. mm 0.12 0.1

13. Connecting rod small end needle

roller bearing internal diameter mm 20 18

14. Clearence between piston

Crown and disc valve mm 1.4 to 1.6 1.4 to 1.6

Downloaded from www.Manualslib.com manuals search engine

 General view of the compressor

Downloaded from www.Manualslib.com manuals search engine

 General Description

Introduction

The Elgi air compressor model TRC 1000 MN UG is driven by an electric motor
by means of resillient flange coupling. It consists of three cylinders arranged
in a ‘W’ form on a crankcase. Dry type air filters are fitted to the suction side of
the LP cylinder heads. The discharge ports of the LP cylinder heads are
connected to the intercooler for effective cooling . Intercooler is connected to
the suction
port of HP cylinder head. The discharge port of the HP cylinder head is fitted
with a motor and mounted on a rigid, compact base. The air filters and other
pipe fittings are all clamped properly to arrest vibration. A fan with a fan guard
is provided to direct cool air on to the compressor unit. The fan draws the air
over the motor thereby cooling the motor also. An eye bolt used for lifting the
motor is provided at the terminal side of the motor. (Fix the eye bolt on top of
motor and lift the motor).

Crankcase

The crankcase is made of high grade cast iron an houses the crankshaft
assembly and cylinders. It act as the sump for lubricating oil and is provided
with a breather, drain plug and a dipstick assembly. The breather maintains a
partial vacuum in the crankcase to facilitate better lubrication.

Cylinder and cylinder head

The cylinders and cylinder heads are made of high grade cast iron and they
have close deep fins for effective cooling. The hardness of the cylinders is
closely controlled to ensure high wear resistance.

Connecting rod crankshaft assembly

The connecting rod and crankshaft assembly is precision machined and

dynamically balanced. The combined crankshaft with web is forged out of
carbon steel, hardened and precision ground. The crankshaft is provided with
single row heavy duty ball bearing at both ends. The main connecting rod big
end is provided with steel bearing rollers and small ends are provided with
needle roller bearings.

Downloaded from www.Manualslib.com manuals search engine

 General Description

Piston and Piston rings

The pistons are of automotive type and made out of low expansion aluminium
alloy. They are provided with plain compression rings, stepped compression
rings and slotted oil control rings. The rings are made of special quality close
grained cast iron and designed for controlling wear and oil consumption to a
minimum. The gudgeon pins are of chrome steel case hardened and precision
ground.

Disc valves

Special type concentric disc valves have been used for suction and discharge
operations. The springs used are of high quality spring steel.

Intercooler, safety valve and aftercooler

The intercooler consists of a series of copper tubes, on which fins are wound
for effective cooling. It is mounted above the motor. It is provided with a safety
valve and a drain valve. The aftercooler is also made of copper tubes with fins
wound on them and arranged together for better cooling. A drain valve is
provided on the aftercooler.

Average Life

This type of coupling does not require any attention during running .

i. The coupling hubs will not require replacement earlier than six years of
continuous use.

ii. Misalignment if any in the coupling will reduce the life of the coupling
element.

10

Downloaded from www.Manualslib.com manuals search engine

 Installation and operation

The following points should be checked during commissioning.

a. Examine the unit for transit damages.

NOTE
BEFORE COMMISSIONING THE COMPRESSOR
Fill up the crankcase with SERVO PRESS 150 oil upto the
maximum mark on the dipstick.

b. Position the compressor in the locomotive and check the level of the
compressor by using a spirit level.
c. Ensure that the compressor unit is properly aligned and all bed bolts
are fully tightened.

d. Rotate the compressor unit by hand and feel whether it is free, except
for compression forces.

e. Connect the motor to a three phase supply and ensure anticlockwise

rotation when viewed from the non-driving end of compressor.

f. Start up the unit and drain intercooler and aftercooler for a few minutes
and also ensure intercooler safety valve is free and functioning
properly.

g. Check if there is any abnormal noise or vibrations. If so, check up and

rectify the defect.

h. If all the above checks are satisfactory, the unit can be commissioned
for regular service.

11

Downloaded from www.Manualslib.com manuals search engine

 Maintenance Schedule

General

Cleanliness and care must be observed whenever inspection and checks are
being carried out on the compressor and 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 immediate attended to. The
unit should be properly maintained as per the undermentioned schedule.

WARNING
Lubricating oil change should be carried out during
Recommended maintenance schedule
Recommended lubricating oil; Servo press 150

NOTE
The compressor should be run for a short while and
draining of the oil should be done when the oil is warm.
Do not use any cleaning agents to clean the interior, when
changing oil.

During trip schedule

a. Clean the compresor thoroughly.

b. Check the oil level in the crankcase. Replenish with the correct grade of
oil if required.

c. Drain the intercooler and aftercooler in order remove the moisture

collected in them. Run the compressor for a few mintues with the drain
valve open, so that the moisture will be removed completely

During trip IA schedule

Check the compressor for satisfactory operation which include :

a. Cleanliness of the compressor.

b. Operational noise and vibration.

c. Tightness of mounting bolts and other fasteners.

12

Downloaded from www.Manualslib.com manuals search engine

 Maintenance Schedule

d. Air leaks at the pipe joints and safety valve.

e. Clean the suction filter element thoroughly by using air from inside to
outside.

f. Check the suction and discharge operations and general performance of

the compressor.

g. Drain the intercooler and aftercooler.

NOTE :

RECOMMENDED GREASE

l SERVOGEM Gr.3 FOR BHARAT BIJILI MOTOR

l LITHIUM BASE Gr.3 FOR CROMPTION MOTOR

During IB schedule

a. All check points indicated under IA schedule to be carried out.

b. Breather valve should be dismantled, cleaned and checked for perfect

seating of the valve.

c. Check the safety valve setting.

d. Visually check the disc coupling for any abnormality in disc back

e. Check the oil level in the crankcase and topup the required quantity of oil

During IC, Schedule

a. All check points indicated under IA, schedule to be carried out.

b. Remove all the disc valves by removing the cylinder heads.

The valves are to be replaced with readily available spare valves since
valves that are removed should undergo thorough cleaning etc.

13

Downloaded from www.Manualslib.com manuals search engine

 Maintenance Schedule

c. Dismantle the disc valves, check the springs, top plates and bottom plates.
There should not be any scratches or damage in the seating of valve
plates. If there is any damage, it should be lapped. If the springs are
damaged, they should be replaced. All the parts should be decarbonised
and thoroughly cleaned in kerosene. Reassemble the valve and assemble
it to the cylinder with new packings.

d. All the pipe lines should be checked for leaks at joints and packings
renewed as necessary.

During AoH Schedule

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.

Check the crankshaft 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.

Maintenance Schedule -Comparison between TRC1000MN and TRC1000MNUG

Maintenance Maintenance
SI
Maintenance Practice schedule for schedule for
No.
TRC 1000 MN TRC 1000 MN UG

1 Check oil level and top up, if required 45 Days 90 Days

2 Greasing of coupling 45 Days Eliminated

3 Intake air filter- Inspect element, clean if dirty 90 Days 180 Days

4 Inlet & Discharge Valve cleaning & Inspection 90 Days 180 Days

5 Drain and refill oil 90 Days 180 Days

6 Replace the Piston Rings, if required 540 Days 720 Days

(AOH -M18) (AOH-M24)

7 Replace all the Pistons, if required 720 Days 1080 Days

(IOH -M24) (IOH-M36)

8 Replace all the Cylinders, if required 720 Days 1080 Days

(IOH -M24) (IOH-M36)

14

Downloaded from www.Manualslib.com manuals search engine

 Repairs

General

Only a skilled technician who knows about the compressor should dismantle
and reassemble the compressor. Before dismantling the compressor, make
sure that it is free of compressed air. Pull the safety valve and ensure this.
Ensure that the electric power is disconnected from the unit.

Accessories

Remove the intercooler after removing the respective pipe fittings and bolts.
Remove the aftercooler and suction filters. Open the drain plug and drain the
oil from the crank case.

Cylinder head, Disc valves, Cylinder

Remove the cylinder head and take out the disc valve. Take care not to damage
the disc valves.While dismantling the disc valve, the position of the springs
should be carefully noted which will help during reassembling. Refer the
exploded view of the disc valve which is self explanatory. If damaged; the
springs should be replaced with new ones. Also check the packings and if
necessary replace by new ones.

Unscrew the cylinder and remove the cylinder. If the cylinders are tightly fixed
to the crankcase rotate the fly end hub. The cylinders will automatically come
up.

Piston assembly

Remove the circlip by using a criclip plier and gently knock out the gudgeon
pin. Inspect for scratces or slackness in the piston boss. If the pin is worn out
use a new pin. Remove the piston rings using a piston ring expander.

Clean the piston rings and the ring grooves in the piston. Measure the piston
size, gudgeon pin bore size, piston ring gaps at butts and side clearances.
Replace the rings as a set when limiting clearances have been reached.

Crankshaft assembly

Disassemble the disc coupling. Then remove the free and cover. Remove the
crankshaft assembly through the fly end cover bore along with the cover.
Using puller remove the fly end cover from the crankshaft assembly. Clean the
crankshaft and connecting rod assembly thoroughly in kerosene and dry with
compressed air. Inspect the bearings, if found damaged, replace them with
new ones.

15

Downloaded from www.Manualslib.com manuals search engine

 Repairs

Crankshaft assembly

Remove the disc coupling. Then remove the free and cover. Remove the crank-
shaft assembly through the fly end cover bore along with the cover.
Using puller remove the fly end cover from the crankshaft assembly. Clean the
crankshaft and connecting rod assembly thoroughly in kerosene and dry with
compressed air. Inspect the bearings, if round damaged, replace them with
new ones.

Bearing

Removing ball bearings from the crankshaft

Take a small steel wedge and gently hammer it keeping in between the
crankweb and the bearing.
Then use a suitable puller and take out the bearings.

Assembling the bearings on the crankshaft

Heat them to a temperature from 100C to 120C in an oil bath or on a hot plate
which is heated by a flame or electricity insert the bearings on the shaft so that
they will slide in and fit tight when cooled.

Assembling connecting rod and crankshaft assembly in the crankcase

Take the connecting rod and crankshaft assembly, clean it and oil the bearings.
Rotate the bearings by hand and check for any tightness. They should have
free rotation. Check whether the splasher pin is secured in position. The flat
sides of the splasher pin should be perpendicular to the axis of the shaft.

Fix the fly end cover on the crankshaft assembly. Insert the crankshaft assembly
through the flyend cover bore on the crankcase. Fix the free end cover on the
other side. Then fasten the end covers bolts uniformly.

16

Downloaded from www.Manualslib.com manuals search engine

 Disc coupling assembly procedure

1. Fit the motor side hub on motor shaft, fix key way grub screw

2. Assemble the coupling spacer on motor side coupling hub.

3. Put the motor on base frame first.

4. Put the compressor on base frame ensuring that the spacer encovers the
compress side hub and lamina screws get through the compressor side
hub flange tighten the compressor side hub to spacer bolts.

5. Locate the compressor properly and tighten it to the base (this is not to be
disturbed further)

6. Maintain 101mm distance (flange to flange) by moving motor towers or

away from compressors

7. Once 101 mm is maintained. Fix the motor to the base frame firmly.

8. Mount dial gauge on compressor side hub so that one dial gauge touches
motor side hub radially and other dial touches fan blade coller (Ø 300)
axially (ensure dial gauge pressure by 2 bar)

9. Adjust ‘0’ on both dials at the top position (i.e., 12’O’ clock position)

10. Take radial / angular readings at 12, 3, 6, 9 ‘O’ clock position record as
follows

11. Sample reading for interpretation - radial allowable limit - 0.85 mm (TIR)

17

Downloaded from www.Manualslib.com manuals search engine

 Disc coupling assembly procedure

INTERPRETATION

These reading confirm the following

1. Motor axis lower than compressor

axis by 0.80 (TIR) i.e., by 0.40 radially

2. Motor is shifted radially by 1.4mm

(TIR)

CORRECTIVE ACTION

a. To adjust the vertical shift (0.8), loose motor foundation bolts add 0.4mm
shims bellow all 4 legs of motor

b. To adjust the horizontal shift [-0.6+(+1.4)=2.0mm] shift motor by side

screws towers left, by keeping a close watch on dial gauge reading till
dial gauge reading reduce to +0.4

c. After above activities, tighten the motor foundation bolts fully, and again
take dial gauge reading for radial.

d. The allowable limit for radial is 0.85 (TIR) as such plaese follow above
procedure till the reading are within limits.

13. Sample reading for interpretation - angular.

Allowable limit - 1.7mm (TIR) at Ø 300

This reading confirm the following motor is

tilted as per figure bellow

Reading taken
from this view

18

Downloaded from www.Manualslib.com manuals search engine

 Disc coupling model assy instructions

CORRECTIVE ACTION

a. It’s required to rotate the motor towards left by keeping the bolt no ‘1’
fixed, loosing bolt no 2,3&4 and by pushing the side screw at bolt
number 4.

b. Shift motor by side screws towers left by keeping a close watch on dial
gauge reading till dial gauge reading.

c. After above activities, tighten the motor foundation bolts fully, and agian
take dial gauge reading for angular.

d. The allowable limit for radial is 1.7mm at Ø 300 (TIR) as such please
follow above procedure till the reading are within limits.

e. Once axial /angular/radial readings are brought within tolerances (i.e.,

25% of the tolerance mentioned on the coupling drawing) fix all the
foundation bolt and tighten all coupling bolts to the required
torque (33 N-m).

Disc pack Spacer

Hub compressor side Disc pack

Hex bolt

Hex nut
Hub motor side
Over load washer

19

Downloaded from www.Manualslib.com manuals search engine

 Radial sample Angular sample Motor position as per radial
Remarks
readings readings reading

CORRECTIVE ACTION
1. Vertical shift (0.2 TIR) is within the limit
no need to add shims.
2. H o r i z o n t a l s h i f t w i t h i n t h e l i m i t
[+0.12+(-0.4)=0.52mm] still you can

Downloaded from www.Manualslib.com manuals search engine

adjust the misalignment. To adjust shift
motor by side screws towers right, by
keeping a close watch on dial gauge
reading till dial gauge reading reduces
Reading taken
to +0.26
from this view
3. To adjust the angular shift it’s required
to rotate the motor towards left by
keeping the bolt no ‘2’ fixed, loosing
bolt no1,3&4 and by pushing the side
screw at bolt number 3, keeping a close
watch on dial gauge reading till dial
gauge reading reduces to ‘0’.

20
Add shim here

1. To adjust angular (1.5) and radial shift

(1.8 TIR), add shims at front foot.
Downloaded from www.Manualslib.com manuals search engine
Radial sample Angular sample Motor position as per radial Remarks
readings readings reading

add shim here

21
1. To adjust angular (1.7) and radial
shift (1.2 TIR), add shims at rear
foot.

add shim here

1. To adjust radial shift (2.0 TIR),add

0.5 shims at front and rear foot.
 Radial sample Angular sample Motor position as per radial
Remarks
readings readings reading

add shim here

1. To adjust radial shift (2.0 TIR),

add 0.5 shims at compressor rear
foot.

Downloaded from www.Manualslib.com manuals search engine

+0.1

FAN DIAL GAUGE TO MEASURE ANGULAR READING

DIAL TO MEASURE RADIAL READING

22
MOTOR
Disc coupling model assy instructions

COMPRESSOR

COUPLING

Dial gauge mounting arrangement

 Torque chart

The following chart gives the tightening for various fasteners used in the
compressor.

Model : TRC 1000MN - UG

Tightening
SI.
Location Thread size torque Values are
No.
in N-m

1. End cover Free-end M8 30 N-m

2. End cover Fly-end M8 30 N-m

3. Crankcase to base M12 50 N-m

4. Motor to base M12 50 N-m

5. Crankcase to Cylinder M12 50 N-m

6. Cylinder to head M12 50 N-m

7. Pipe flange joints M12 50 N-m

8. Pipe flange joints M10 30 N-m

9. Disc coupling bolt M8 33 N-m

10. Drain plug 3/8" BSP 30 N-m

11. Dipstick ½" BSP 35 N-m

23

Downloaded from www.Manualslib.com manuals search engine

 Troubleshooting

Problem : Pressure build time excessive

Check Remedy

Suction air filter is

clogged ä Increase frequency of cleaning.
ä

Pipe line leaking Increase frequency with more level in

ä periodic check of oil.
ä

Disc valves defective . Remove cylinder head and the disc

Carbon deposits too ä valves, decarbonisation
much should be done.
ä

Check the ring gap, if required

Piston rings worn out ä change the rings.

Problem : Low pressure safety valve operates though the

specified pressure is not reached

Check Remedy

Check the safety valve components

safety valve is not
functioning properly. ä for correctness & reset to
recommended rating.

Problem : LP safety valve operates during compressor

running
Check Remedy

Disc valve in the HP Check the disc valve components,

cylinder not functioning ä clean the dust if any and rectify the
properly. defect.

24

Downloaded from www.Manualslib.com manuals search engine

 Troubleshooting

Problem : Abnormal noise and knocking of

compressor

Check Remedy

Connecting rod &

crankshaft assembly should be
Crankshaft assembly ä reconditioned
defective.
ä

Journal bearings are

worm out.
ä Change the bearings.
ä

Gudgeon pin loose in ä Change piston and check for

piston lubrication
ä

Check and if necessary replace the

Disc valve is defective ä parts required.
ä

Coupling is wornout
ä Check the coupling hubs & change
(Loose on the bore) if required.
ä

Key of the compressor ä Replace with correct size key.

and motor loose.

Problem : Compressor overheating

Check Remedy

Dirty oil Oil, level low ä Change oil, Fill correct grade of oil
upto maximum level. (SERVO 150)
ä

Breather not working ä Open, clean and refit after checking.

25

Downloaded from www.Manualslib.com manuals search engine

 Troubleshooting

Problem : Compressor seizure / piston scoring

Check Remedy

Insufficient lubrication
or oil become too thick ä Maintain correct oil level or change
the oil.
ä

Incorrect direction of
rotation
ä Correct the direction of rotation.
ä

Insufficient clearence Correct as per recommendation.

between cylinder, piston ä Maintain clearence as per chart
and rings (if fitted new) given.

Problem : Oil carry over in compressor air

Check Remedy

Oil leaking through Remove the piston, cylinder and check

piston ring gap and ä the bore clearence. For recommenda-
piston tion, please refer technical data.
ä

Change to recommended
Oil viscosity to low. ä grade.

Problem : Oil leak through breather

Check Remedy

Breather valve not Open, clean and refit the breather.

working, Piston ring ä Loosen the piston rings. If broken,
stuck in grooves or change the rings as a set.
broken.
ä

Piston to cylinder ä Check and change.

excessive.

26

Downloaded from www.Manualslib.com manuals search engine

 Preservation

Short duration (Less than one month)

Allow the unit to run in no load condition for some time, then close the unit and
keep it under shelter, free from dust and moisture.

Long duration (More than one month)

Remove the air filter and pour 50ml preservation oil (Servo press 150) through
suction port of each LP cylinder. Remove the suction pipe of H.P cylinder,
pour rust prevention oil for the HP cylinder and then allow the unit for a few
minutes. Drain oil from the crankcase.

Now assemble the suction pipe and air filter, cover the whole unit. Keep the
unit under shelter. The unit should be thoroughly cleaned and examined every
month for corrosion prevention and free rotation.

27

Downloaded from www.Manualslib.com manuals search engine

 Motor maintenance

General

The motor used will be of reputed make and thoroughly inspected to ensure
long and trouble free service.

Aligning of motor & Compressor

While assembling fan flange and coupling over the motor shaft only appropriate
tools should be used. While changing the fan, complete fan with flange
assembly should be changed to avoid unbalance or after changing the fan ;
the fan with flange assembly should be balanced. The shafts of the compress
and the motor should perfectly be levelled and aligned.long and trouble free
service.

Electrical Connections

The connection on the terminal board of the motor should be in accordance

with the wiring diagram which is pasted in the inside portion of the terminal
cover. Connect earthing wire to the terminal marked with earthing symbol on
the terminal board. Separate earthing links are provided on the main body of
the motor and this should also be connected with a cable of suitable cross
section as per IS 900. All fixed electrical connections should be checked for
tightness. To change the direction of rotation of the motor any two of the supply
leads (phases) should be interchanged. Motor starters of air brake contactors
with overload relays shall be used. In addition back up fuses of the HRC
cartridge type are essential to protect the motor insulation as well as thermal
overload relays of the starter against short circuit.

Maintenance

Motors should be cleaned by blowing dry air at regular intervals to keep the
ventilating passages clean.The bearings are prelubricated with lithium based
grease having a dripping point above 160OC. Onlyrecommended grade of
grease should be used for the bearings. In case of motors that have regreasing
attachment frame size upto and including AM 200 and AJ 180, the grease in
the bearings shall be changed at an interval of 2 years. While regreasing, the
bearings and bearing covers should be well cleaned and then fill the grease.

28

Downloaded from www.Manualslib.com manuals search engine

 Motor maintenance

In case the motor is stored idle for long period or if it is transported under very
damp condition, the insulation resistance should be checked before connecting
it to the supply. The insulation resistance of the motor shall be measured
between the windgings of the motor and its frame by means of a megger. If
the measured insulation resistance of the motor is less than IMDHM/KV when
the motor is cold, it should be dried out before rated voltage is applied to the
terminals of the motor.

The motor can be dried by placing heaters or lamps around it and inside also
or by blocking the motor so that it cannot rotate and then apply such a low
voltage to the starter terminal that full load current flow in the starter. Care
must be taken during the drying out the windings that the temperature of the
induction coil does not exceed 150 OC which is the maximum allowable
temperature for class F insulation.

29

Downloaded from www.Manualslib.com manuals search engine

 Standard and special tools

10
9

1 2 3 4

5 6 7

Fig. Description Part No

No

1 Ring gauge for 60 dia piston assembly

(Ring Inserting tool) 000415230

2 Ring gauge for 100 dia piston assembly

(Ring Inserting tool) 000415240

3 Pusher with nut for compressor side 000427400

4 Pusher with nut for motor side 000427420

5 Spacer flange for pusher common

for compressor and motor side 000427410

6 Coupling removal tool Motor side and

compressor side 070312130

7 Tool coupling axial measuring 070312140

8 Tool coupling dial holder 070312150

9 Radial dial gauge M008992184

10 Angular dial gauge M000057186

30

Downloaded from www.Manualslib.com manuals search engine

 Standard and special tools

SL. No Standard and special tools

1 10-11 Double end spanner

2 13 Box spanner

3 18-19 Double end spanner

4 19 Box spanner

5 20-22 Double end spanner

6 25-28 Double end spanner

7 38-41 Double end spanner

8 12mm stud tightening spanner

9 Ring Expander (Dia 100)

10 Ring Expander (Dia 60)

11 Circlip plier

12 Pipe wrench 9”

13 Screw driver 6”

31

Downloaded from www.Manualslib.com manuals search engine

 Recommended spares

AOH spares for TRC 1000 MN UG code : 072404009

S.No. Drg. /Part No. Description Qty.

CONSISTING OF
1 000431990 GASKET FREE END 1

2 000431980 GASKET FLY END 1

3 000524060 PKG BIG DIA 60 D/V TRC I000MN 2

4 000524070 PKG SMALL DIA 6O D/V TRC 1000MN 1

5 000519210 GASKET BIG CYL TO D/V DIA100 4

6 000519220 GASKET SMALL D/V TO CYL HEAD 2

7 00041004C GASKET 0.8 C/CASE TO CYL TS05 3

8 000430050 PKG DS ASSY TRC1000MN/1000B 1

9 000510850 RING O 5.28X1.78 SS15 HV HP 2

10 000424060 PKG HV2O/25/30 SP10/12/15/20 1

11 000521960 RING PKG 21X25X2 (DIPSTICK) 1

12 00041004A GASKET 0.25C/CASE TO CYL TS05 3

13 00041004B GASKET 0.4 C/CASE TO CYL TS05 3

14 072404039 PISTON RING SET DIA 100 MN UG 2

15 072404049 PISTON RING SET DIA 60 MN UG 1

16 000435920 VALVE SEAT SN 1

17 000519930 VALVE SEAT DRAIN VALVE 2

18 000415160 BOTTOM PLATE 2

19 000415170 SUCTION VALVE SPRING 2

20 000415180 SUCTION VALVE PLATE 2

32

Downloaded from www.Manualslib.com manuals search engine

 Recommended spares

AOH spares for TRC 1000 MN UG code : 072404009

S.No. Drg. /Part No. Description Qty.

21 000415190 DELIVERY VALVE PLATE 2

22 000415200 DELIVERY VALVE SPRING 4

23 000424350 VALVE SPRING SUC TRC 1000MN 2

24 000424340 VALVE PLATE SUCTION TRC 2000 1

25 000424330 VALVE PL DEL TRC1000MN 1

26 000424360 VALVE SPRING DEL TRC I000MN 2

27 000510060 VALVE BREATHER 1

28 000420350 SEAL OIL B45X60X12.5 1

29 000424330 VALVE PL DELIVERY 1

30 000917218 CIRCLIP INTERNAL 18 MM 2

31 000917220 CIRCLIP INTERNAL 20 MM 4

32 070408090 GASKET LP OUTLET 3

33 07040544A GASKET FLANGE 5

33

Downloaded from www.Manualslib.com manuals search engine

 Recommended spares

IOH spares for TRC 1000 MN UG code : 072404019

S.No. Drg. /Part No. Description Qty.

CONSISTING OF

1 000424060 PKG HV2O/25/30 SP10/12/15/20 1

2 000430050 PACKING DS ASSY 1

3 000431980 GASKET FLY END 1

4 000431990 GASKET FREE END 1

5 000510850 RING 0 5.28 X1.78 SS15 HV HP 2

6 000519210 GASKET BIG CYL TO D/V DIA100 4

7 000519220 GASKET SMALL D/V TO CYL HEAD 2

8 000521830 RING PKG 33.5X38X3 3

9 000521930 RING PKG CONNECTOR HSG TO ERMETO 3

10 000521960 RING PKG 21X25X2 (DIPSTICK) 1

11 000524060 PKG BIG DIA 60 D/V TRC I000MN 2

12 000524070 PKG SMALL DIA 6O D/V TRC 1000MN 1

13 00041004C GASKET 0.8 C/CASE TO CYL TS05 3

14 00041004A GASKET 0.25C/CASE TO CYL TS05 3

15 00041004B GASKET 0.4 C/CASE TO CYL TS05 3

16 000420350 SEAL OIL B45X60X12.5 SS07/10 1

17 000466780 DISC END TRC 1000MN 1

18 070405060 PISTON AND GP DIA60 RR15070 1

19 000477770 PISTON & GP DIA100 SSO7/10 2

20 000511230 NIPPLE HEX 3/4"X3/4" BSPX40 1

21 000514550 STUD M12X54 60 CYL 6

22 000514560 STUD M12X45 C/CASE TO 50CYL 8

23 000518830 STUD M12X70 SS 02/03/05 TSO2/03 1

34

Downloaded from www.Manualslib.com manuals search engine

 Recommended spares

IOH spares for TRC 1000 MN UG code : 072404019

S.No. Drg. /Part No. Description Qty.

25 000520130 STUD M12X60 C/CASE TO 70CYL SS 4

26 000520140 STUD M12X75 100CYL B/G FIXING 5

27 000906183 BOLT HEX M12X30 8.8 ZYP 5-8M 1

28 000948012 HEX. NUT M 12 24

29 000996112 SPRING WAHSER M12 24

30 072404039 PISTON RING SET DIA 100 MN UG 2

31 072404049 PISTON RING SET DIA 60 MN UG 1

32 000917218 CIRCLIP INTERNAL 18 MM 2

33 000917220 CIRCLIP INTERNAL 20 MM 4

34 070308440 CYLINDER DIA 100 M/C TRC1000BS 2

35 070306140 CYL DIA60 D/V M/C RR14100 1

36 070408170 PIPE I/C TO HP 1

37 070408200 PIPE HP CYL TO AFTER COOLER 1

38 070408180 DELIVERY PIPE ASSLY 1

39 A020045 VALVE ASSY DRAIN 1/4" BSP MN 1

40 070309310 AIR FILTER ASSY, TRC1000MN UG 2

41 A070075 DIPSTICK WITH CHAIN TRC 1000MN 1

42 A020030 VALVE ASSY BREATHER ALUMINUM 1

43 A020042 D/V ASSY DIA 100 2

44 A070017 VALVE ASSY DISC DIA 60 TRC 1000MN 1

45 A070025 VALVE ASSY SAFETY 3/8"BSP MN 1

46 070408090 GASKET LP OUTLET 3

47 07040544A GASKET FLANGE 5

35

Downloaded from www.Manualslib.com manuals search engine

 Recommended spares

POH spares for TRC 1000 MN UG code : 072404029

S.No. Drg. /Part No. Description Qty.

CONSISTING OF

1 072404019 KIT -IOH SPARES TRC1000MNUG

2 A070069 CRANK SHAFT ASSY & BRG 1

3 070309680 INTER COOLER COMPLETE 1

4 070309690 AFTER COOLER COMPLETE 1

5 070310410 DISC COUPLING TRC1000MN UG 1

6 A070047 C/FAN & FLG ASSY TRC1000MN 1

Piston ring set dia 100 for TRC 1000 MN UG code : 072404039

S.No. Drg. /Part No. Description Qty.

1 ---- RING TPC DIA100 1

2 ---- RING SC DIA100 2

3 ---- RING SOC DIA100 2

Piston ring set dia 60 for TRC 1000 MN UG code : 072404049

S.No. Drg. /Part No. Description Qty.

1 ---- RING TF PERMASEAL DIA60 RR1507 2

2 ---- RING OIL DIA60 RR15070 2

36

Downloaded from www.Manualslib.com manuals search engine

 Spare parts list

37

Downloaded from www.Manualslib.com manuals search engine

 Fig. 1 Package assy - TRC 1000 MN - UG (TPL No. : S 07096)

38

Downloaded from www.Manualslib.com manuals search engine

 Package assy - TRC 1000 MN - UG (TPL No. : S 07096)

Fig. No. Description Qty Drg./Part No.

1 TRC 1000 MN UG RAC UNIT 1 -----

2 BASE 1 000221720

3 COOLING SYSTEM 1 -----

4 DRIVE SYSTEM 1 -----

5 FAN GUARD ASSY 1 070310400

39

Downloaded from www.Manualslib.com manuals search engine

 Fig. 2 Unit assy - TRC 1000 MN - UG

40

Downloaded from www.Manualslib.com manuals search engine

 RAC Unit assy - TRC 1000 MN - UG

S.No. Drg. /Part No. Description Qty.

1 070301120 Crank shaft Assy (A070069) 1

2 020494550 Piston Assy Dia 100 2

3 000413120 Piston Assy Dia 60 1

4 000312040 Disc valve Dia 100 (A020042) 2

5 000313810 Disc valve Dia 60 (A070017) 1

6 000438600 Drain plug 1

7 A020030 Breather 1

8 070309960 C/Case M/C 1

9 000431990 Gasket free end cover 1

10 000318090 Cover free end 1

11 000996108 Spring washer M8 14

12 000906115 Bolt Hex M8x20 14

13 000420350 Oil seal 1

14 000431980 Gasket Fly end cover 1

15 000317770 Cover Fly end 1

16 000521860 Packing ring 17x22x2 1

17 000514560 Stud M12x45 8

18 00041004C Gasket C/Case to Cylinder 3

19 000906183 Bolt Hex M12x30 4

20 070308440 Cylinder Dia 100 2

21 000996112 Spring washer M12 30

22 000948012 Hex Nut M12 24

23 000520130 Stud M12x60 2

24 000520140 Stud M12x75 6

41

Downloaded from www.Manualslib.com manuals search engine

 Fig. 2 Unit assy - TRC 1000 MN - UG

42

Downloaded from www.Manualslib.com manuals search engine

 RAC Unit assy - TRC 1000 MN - UG

S.No. Drg. /Part No. Description Qty.

25 000519210 Gasket Big DV Dia 100 4

26 000519220 Gasket small DV Dia 100 2

27 070309930 Head M/C Dia 100 Cylinder 2

28 000514550 Stud M12x54 7

29 070306140 Cylinder Dia 60 DV 1

30 000518830 Stud M12x70 1

31 000524060 Gasket Big DV Dia 60 2

32 000524070 Gasket small DV Dia 60 1

33 000917218 Circlip Internal 2

34 070307830 Cylinder Head Dia 60 DV 1

35 000521960 Packing ring 21x25x2 1

36 070400690 Dipstick with chain 1

37 000466020 Lock Nut 1/2" BSP 1

38 00041361B Pipe breather 1/2" BSP 1

39 000436650 Reducer 1"x1/2" BSP 1

40 000466660 Key 12x8x60 1

41 000903361 BRG 6310 2

42 070408160 Suction pipe LH 1

43 070404970 Gasket Filter 2

44 070408150 Suction pipe RH 1

45 070309310 Filter Assy 2

43

Downloaded from www.Manualslib.com manuals search engine

 Fig. 3 Cooling System

44

Downloaded from www.Manualslib.com manuals search engine

 Cooling system

Fig. No. Description Qty Drg./Part No.

1 Drain valve 1/4" BSP, I/C,/A/C 2 A020045

2 After cooler complete 1 070309690

3 Holder RH I/C 1 000445950

4 Cooler holder with clamp 2 000445940

5 Inter cooler complete 1 070309680

6 LP outlet manifold 1 070309770

7 Gasket dia 90 head 3 070408090

8 Pipe I/C to HP 1 070408170

9 Gasket cooler pipe 5 07040544A

10 Bolt hex M12 x 45 2 000906186

11 Pipe HP cyl to A/C 1 070408200

12 Delivery pipe assy 1 070408180

13 Safety valve 3/8" BSP 1 A070025

14 Bolt hex M10 x 30 14 000906145

15 Spring washer M10 29 000996110

16 Bolt hex M10 x 45 8 000906148

17 Bolt hex M10 x25 2 000906144

18 Bolt hex M12 x 30 4 000906183

19 Spring washer M12 4 000996112

20 Bolt hex M10 x 40 4 000906148

21 Flange with Ebow 1 000480920

22 Gasket 1 000424060

23 Nut hex M12 2 000948012

24 Nut hex M10 6 000948010

45

Downloaded from www.Manualslib.com manuals search engine

 Fig. 3 Motor & fan assy

46

Downloaded from www.Manualslib.com manuals search engine

 Motor & fan assy

Fig. No. Description Drg./Part No.

1 C/Fan & FLG assy A 07 0047

2 TRC 1000 MN 14 HP Motor 10*490369

3 Disc coupling 07 03 1041 0

4 Bolt, Hex M8 x 35 00 09 0611 8

5 Nut, Hex M8 00 09 4800 8

47

Downloaded from www.Manualslib.com manuals search engine

 6

Fig. 4 Piston Assembly Dia 100 (Part No. 00 04 1311 0)

Keep the “PIP” mark in top

during assy

Rail opening & spacer opening

should be at 90 Deg difference
approximately

Fig. 5 Piston Assembly Dia 60 (Part No. 07 04 0508 0)

48

Downloaded from www.Manualslib.com manuals search engine

 Piston assy - dia. 100

Fig. No. Description Qty. Drg./Part No.

PISTON ASSY. DIA. 100 (Incl.No.1 to 5) 1 00 04 1311 0

1 Taper plain compression ring 1 -----

2 Stepped compression ring 2 -----

3 Slotted oil control ring 2 -----

Piston with G.Pin (Including 4,5 & 6) 1 00 04 7777 0

4 Piston dia. 100 1 -----

5 Gudgeon pin dia. 20 1 00 05 1419 0

6 Circlip B20 2 00 09 1722 0

Kit, Ring set (Incl No. 1,2,3) 2 07 24 0403 9

Piston assy - dia. 60

Fig. No. Description Qty. Drg./Part No.

PISTON ASSY DIA 60 (Incl.No.1 to 4) 1 07 04 0508 0

1 Ring perma-seal 2 -----

2 Ring oil 3-piece 2 -----

Piston with G-pin (Including 3,4&5) 1 07 04 0506 0

3 Piston dia 60 1 -----

4 Gudgeon pin Dia 18 1 00 05 1418 0

5 Circlip 18mm 2 00 09 1721 8

Kit, Ring set (Incl No. 1,2,) 2 07 24 0404 9

49

Downloaded from www.Manualslib.com manuals search engine

 5

Fig. 6 Air filter assembly (Part No. 070309310)

50

Downloaded from www.Manualslib.com manuals search engine

 Fig. 5 Air filter assembly (07 03 0931 0)

Fig. No. Description Qty. Drg./Part No.

1 Rubber bush 1 070408750

2 Bottom cover 1 -----

3 Filter Element 1 070407510

4 Sealing ring 1 070408760

5 Top cover 1 -----

51

Downloaded from www.Manualslib.com manuals search engine

 Fig. 6 Drain valve assy Fig. 8 Breather valve assy
1/4” BSP

52

Downloaded from www.Manualslib.com manuals search engine

 Drain valve assy - 1/4” BSP - A020045

Fig. No. Description Qty. Drg./Part No.

1 Housing 1 -----

2 Cone seat 1 -----

3 Valve seat 1 00 05 1993 0

Breather valve assy - A020030

Fig. No. Description Qty. Drg./Part No.

1 Breather bottom 1 -----

2 Breather valve 1 00 05 1006 0

3 Breather top 1 -----

4 C.S. Screw M6 x 9 2 00 05 2069 0

53

Downloaded from www.Manualslib.com manuals search engine

 11
10
9
8
7
6
5
4
3
2
1

Disc valve assembly - Dia 100

9
8
7
6
5
4
3

Disc valve assembly - Dia 60

54

Downloaded from www.Manualslib.com manuals search engine

 Disc valve assembly

Disc valve assembly - Dia 100

Fig. No. Description Qty. ELGI Part No.

DISC VALVE ASSEMBLY A 02 0042

DIA.100 1 (00 03 1204 0)
1 Bottom seat plate 1 -----
2 Stud M10 x 35 1 00 05 1915 0
3 Bottom plate for suction valve 1 00 04 1516 0
4 Suction valve spring 1 00 04 1517 0
5 Suction valve plate 1 00 04 1518 0
6 Delivery valve plate 1 00 04 1519 0
7 Delivery valve spring 2 00 04 1520 0
8 Pin 1 00 05 1916 0
9 Top seat plate 1 -----
10 Spring washer M10 1 00 09 9611 0
11 Hex. nut M10 1 00 09 4801 0
(Kit, Disc valve Dia 100 (Consist of items 5,6,7&8) 1 02 24 0098 9

Disc valve assembly - Dia 60

Fig. No. Description Qty. ELGI Part No.

DISC VALVE ASSEMBLY 1 A 07 0017
DIA.60 (00 03 1381 0)
1 Bottom seat plate 1 -----
2 Stud M8 x 32 1 00 05 2259 0
3 Suction valve spring 2 00 04 2435 0
4 Suction valve plate 1 00 04 2434 0
5 Delivery valve plate 1 00 04 2433 0
6 Delivery valve spring 2 00 04 2436 0
7 Top seat plate 1 -----
8 Spring washer M8 1 00 09 9610 8
9 Hex. nut M8 1 00 09 4800 8
(Kit, Disc valve Dia 60 (Consist of items 3,4,5 &6) 1 07 24 0098 9

55

Downloaded from www.Manualslib.com manuals search engine

 Notes

56

Downloaded from www.Manualslib.com manuals search engine

 Notes

57

Downloaded from www.Manualslib.com manuals search engine

 Notes

58

Downloaded from www.Manualslib.com manuals search engine

 Notes

59

Downloaded from www.Manualslib.com manuals search engine

 INSPECTION AND SERVICE RECORD

Scheduled date Results of inspection and outline of service

Date of Date of Inspected or
inspection completion of next inspection Oil Piston Ring & serviced by
of service and service Air valve Others
change Cylinder

Downloaded from www.Manualslib.com manuals search engine

 ELECTRIC POWERED
RECIPROCATING AIR COMPRESSORS

for Electric Locomotive

2 Stage 3 Cylinder

MODEL : TRC 1000 MN - UG

BASE MOUNTED

OPERATION AND MAINTENANCE MANUAL

PARTS MANUAL

Downloaded from www.Manualslib.com manuals search engine

 ©
ELGI EQUIPMENTS LIMITED
Singanallur, Coimbatore, TN - 641 005, INDIA.

Part / Document No.

Revision Status
R00 - First Edition : June 2010
R01 - First Revision : June 2012
R02 - Second Revision : August 2012

Price : INR 500.00

Contact Info :
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005, INDIA.

Tel : 91 - 422 - 2589555

Fax : 91 - 422 - 2573697 (Domestic Business)
91 - 422 - 2589401 (International Business)

e-mail : info@elgi.com
ccs@elgi.com
www.elgi.com

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
 64

Downloaded from www.Manualslib.com manuals search engine

 List of Contents

CHAPTER-i
OPERATION AND MAINTENANCE MANUAL

User Information

Safety

Do’s and Don’ts

Specification and Salient features

Installation

System Operation

Functions of Vaious Systems

Safety and Interlocking Devices

Electrical Systems

Maintenance

Repair schedule

Coupling assy

Trouble Shooting

Preservation

Motor maintenance

Standard & special tool

Recommended Spares

iii
65

Downloaded from www.Manualslib.com manuals search engine

 List of Contents

CHAPTER-iI
PARTS LIST MANUAL

Reciprocating air compressor package

Reciprocating air compressor unit

Cooling system

Motor & fan assembly

Piston assembly

Airfilter assembly

Drain valve assembly

Breather valve assembly

Disc valve assembly

iv
66

Downloaded from www.Manualslib.com manuals search engine

 Machine Identification and
Sale Record
Owner’s name :

Address :

Model :

FAB. No. :

Year of manufacturing :

Motor :

Capacity :

Rated Pressure :

Date of delivery :

Dealer’s name / code :

Dealer’s signature and stamp

Note : The warranty on this compressor is valid only if all the details
above are filled and the dealer stamps and sign this page

v
67

Downloaded from www.Manualslib.com manuals search engine

 Message from the Managing Director

Dear ELGI customer,

It gives me great pleasure to welcome you to the family of users of

compressors from ELGI, among the most sophisticated reciprocating air
compressors available in the world today.

ELGI has designed your compressor to be reliable, safe, easy to maintain

and friendly to use in meeting your compressed air requirements. This
user manual will enable you to use the compressor optimally. Please
familiarise yourself with all the information it contains.

I look forward to your continued satisfaction as a compressor user. ELGI

honoured to be your choice for all your compressed air needs.

Yours sincerely,

Jairam Varadaraj
Managing Director

vi
68

Downloaded from www.Manualslib.com manuals search engine

 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 partnerships and
continuous research and development. Over the years, it emerged as a
multi-product multi-market enterprise providing total compressed air
solutions in all segments. Elgi’s design capabilities translated into wide
range of products ranging from oil-lubricated and oil-free rotary screw
compressors, oil-free reciprocating compressors and centrifugal
compressors.

Screw compression elements are manufactured in-house using

state-of-the-art machining centres for rotor grinding and machining intrinsic
castings of various sizes. Elgi’s own çV (eta-V) profile rotors ensure
energy-efficient 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 domestic 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
69

Downloaded from www.Manualslib.com manuals search engine

 Introduction

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

Please check and ensure OPERATION AND MAINTENANCE MANUAL AND

PARTS MANUAL are receiving along with the compressor. this Operation and
Maintenance Manual has been specially designed keeping you in mind, so
that you can get the most out of ELGI Compressor. Before you start using your
compressor, do go through this manual thoroughly. It contains vital information
on operations and useful tips that will keep your compressor running as good
as a new compressor,year after year.

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

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

viii
70

Downloaded from www.Manualslib.com manuals search engine

 Users’ important information

Read and understand all the operating instructions, safety precaution and
warnings in the Instruction Manual before operating or maintaining this
compressor.

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

Basic safety precautions that are outlined in the “SAFETY” section of this
Instruction Manual have to be followed with utmost care through out the life of
the equipment.

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

Attend to any signs of minor irregularities immediately if neglected, they could

become worse.

Ensure the Operation Instruction Manual be made available to the

compressor operating personnel at all time.

While ordering spare parts the following particulars must be clearly

mentioned to ensure supply of the right spares.

1. MODEL

2. FAB NUMBER

3. YEAR OF MANUFACTURE

4. PART NAME

5. PART NUMBER

6. REQUIRED QUANTITY

ix
71

Downloaded from www.Manualslib.com manuals search engine

 Users’ important information

In case of any requirements of spares or service, please contact our

nearest branch office or distributors

Due to improvements being made constantly and continuously, the

illustrations and descriptions on this manual are not binding.

SAFETY

IMPORTANT SAFETY INSTRUCTIONS FOR USE OF THE

COMPRESSOR.

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

NOTE
Make sure this manual is read and carefully understood
before starting/ operating this machine.
Proof of purchase will be required for warranty
service.

x
72

Downloaded from www.Manualslib.com manuals search engine

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

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

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

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

xi
73

Downloaded from www.Manualslib.com manuals search engine

 Customer Care System (CCS)

CUSTOMER CARE SYSTEM (CCS)

ELGI provides dedicated customer care and after-sales support through the
CCS, a computerized 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 customer complaints are logged,
but also attended on time every time.

Enquiries

A number of calls received by the CCS related to customers’ queries

regarding products and spare parts are noted and basic information on
product specifications and usage are provided. The caller is informed about
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.

xii
74

Downloaded from www.Manualslib.com manuals search engine

 Customer Care System (CCS)

CCS-Working Hours

The CCS at ELGI works for six days a week from 08.30 to 21.30 IST (Monday
to Saturday)

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,

Andhra Pradesh, Andaman & Nicobar Islands

Western Region : Maharashtra, Gujarat, Madhya Pradesh, Goa,

Lakshadweep Islands

Eastern Region : Orissa, Chattisgarh, Jharkhand, West Bengal, Bihar

and the North-Eastern States

Northern Region : Rajasthan, Uttar Pradesh, Delhi, Haryana, Punjab,

Uttaranchal, Himachal and Jammu Kashmir

Other Contact Numbers :

The CCS can also be availed through the following numbers.

Telephone : 0422-2589206 / 2589241 / 2589242 / 2589243 2589244 /

2589245 / 9790021100

Fax : 0422-2589240

You may use the CCS by sending e-mail to :

CCS@elgi.com

Customer Satisfaction Survey :

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

xiii
75

Downloaded from www.Manualslib.com manuals search engine

 76

Downloaded from www.Manualslib.com manuals search engine

 77

Downloaded from www.Manualslib.com manuals search engine

 78

Downloaded from www.Manualslib.com manuals search engine

 79

Downloaded from www.Manualslib.com manuals search engine

 INSPECTION AND SERVICE RECORD

Scheduled date Results of inspection and outline of service

Date of Date of Inspected or
inspection completion of next inspection Oil Piston Ring & serviced by
of service and service Air valve Others
change Cylinder

Downloaded from www.Manualslib.com manuals search engine

80
 81

Downloaded from www.Manualslib.com manuals search engine