ELGi TRC 1000 MN UG Owner's Manual
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ELGi TRC 1000 MN UG Owner's Manual

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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.
1

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Summary of Contents for ELGi TRC 1000 MN UG

  • Page 1 Do’s and Dont’s Read the manual in detail and follow the instructions. Clean the air compressor package regularly. Keep the air filter clean. Use only genuine spares. Maintain correct oil level. Use only clean, recommended lubricants. Use proper tools. Drain the condensate daily by opening the drain valve. Attend immediately to anything unusual with the air compressor.

  • Page 2: Safety Instructions

    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.
  • Page 3 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.
  • Page 4 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.

  • Page 5: Technical Specifications

    Technical Specifications Model TRC 1000 MN UG Type Reciprocating, Air cooled, ‘W’ type and oil Splash lubricated Working pressure kgf/cm 10.5 Displacement m /h 78.48 46.19 1308 Free air delivery m /h 60.00 35.32 1000 Cylinder size & stroke length 100 x 60 x 100 : 85mm No.
  • Page 6 Technical Specifications Unit Coupling Model Disc type coupling Suction filter a. Type Dry type Motor Make a. Make CROMPTON / BHARAT BIJILI b. Type TEFC, Sqiurrel cage induction c. Power d. Voltage Base voltage 415V (290-500v) e. Rated current f. No. of phases Three phase conn.
  • Page 7 Technical Specifications Cylinder, Piston and Piston ring size SI.No Description +0.01 +0.01 0.00 0.00 Cylinder bore Dia 100 Dia 60 Dia 99.835 - Dia 59.941 - Piston Dia 99.855 Dia 59.915 0.000 0.000 -0.005 -0.005 Gudgeon pin size Dia 20 Dia 18 Clearance in cylinder Normal...

  • Page 9: General Description

    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.
  • Page 10 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.
  • Page 11 Installation and operation The following points should be checked during commissioning. 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. Position the compressor in the locomotive and check the level of the compressor by using a spirit level.

  • Page 12: Maintenance Schedule

    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.
  • Page 13 Maintenance Schedule Air leaks at the pipe joints and safety valve. Clean the suction filter element thoroughly by using air from inside to outside. Check the suction and discharge operations and general performance of the compressor. Drain the intercooler and aftercooler. NOTE : RECOMMENDED GREASE SERVOGEM Gr.3 FOR BHARAT BIJILI MOTOR...
  • Page 14 Maintenance Schedule -Comparison between TRC1000MN and TRC1000MNUG Maintenance Maintenance Maintenance Practice schedule for schedule for TRC 1000 MN TRC 1000 MN UG Check oil level and top up, if required 45 Days 90 Days Greasing of coupling 45 Days Eliminated...
  • Page 15 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.
  • Page 16 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.
  • Page 17 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.
  • Page 18 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.
  • Page 19 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.
  • Page 22 Disc coupling model assy instructions...
  • Page 23 Torque chart The following chart gives the tightening for various fasteners used in the compressor. Model : TRC 1000MN - UG Tightening torque Values are Location Thread size in N-m End cover Free-end 30 N-m End cover Fly-end 30 N-m Crankcase to base 50 N-m Motor to base...

  • Page 24: Troubleshooting

    Troubleshooting Problem : Pressure build time excessive Check Remedy Suction air filter is ä Increase frequency of cleaning. clogged Increase frequency with more level in Pipe line leaking ä periodic check of oil. Remove cylinder head and the disc Disc valves defective . ä...
  • Page 25 Troubleshooting Abnormal noise and knocking of Problem : compressor Check Remedy Connecting rod & crankshaft assembly should be ä Crankshaft assembly reconditioned defective. Journal bearings are ä Change the bearings. worm out. Change piston and check for Gudgeon pin loose in ä...
  • Page 26 Troubleshooting Problem : Compressor seizure / piston scoring Check Remedy Insufficient lubrication Maintain correct oil level or change ä or oil become too thick the oil. Incorrect direction of ä Correct the direction of rotation. rotation Insufficient clearence Correct as per recommendation. ä...
  • Page 27 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.
  • Page 28 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 ;...
  • Page 29 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.
  • Page 30 Standard and special tools Fig. Description Part No Ring gauge for 60 dia piston assembly (Ring Inserting tool) 000415230 Ring gauge for 100 dia piston assembly (Ring Inserting tool) 000415240 Pusher with nut for compressor side 000427400 Pusher with nut for motor side 000427420 Spacer flange for pusher common for compressor and motor side...
  • Page 31 Standard and special tools SL. No Standard and special tools 10-11 Double end spanner 13 Box spanner 18-19 Double end spanner 19 Box spanner 20-22 Double end spanner 25-28 Double end spanner 38-41 Double end spanner 12mm stud tightening spanner Ring Expander (Dia 100) Ring Expander (Dia 60) Circlip plier...

  • Page 32: Recommended Spares

    Recommended spares AOH spares for TRC 1000 MN UG code : 072404009 Drg. /Part No. Description Qty. S.No. CONSISTING OF 000431990 GASKET FREE END 000431980 GASKET FLY END 000524060 PKG BIG DIA 60 D/V TRC I000MN 000524070 PKG SMALL DIA 6O D/V TRC 1000MN...
  • Page 33 Recommended spares AOH spares for TRC 1000 MN UG code : 072404009 Drg. /Part No. Description Qty. S.No. 000415190 DELIVERY VALVE PLATE 000415200 DELIVERY VALVE SPRING 000424350 VALVE SPRING SUC TRC 1000MN 000424340 VALVE PLATE SUCTION TRC 2000 000424330 VALVE PL DEL TRC1000MN...
  • Page 34 Recommended spares IOH spares for TRC 1000 MN UG code : 072404019 Drg. /Part No. Description Qty. S.No. CONSISTING OF 000424060 PKG HV2O/25/30 SP10/12/15/20 000430050 PACKING DS ASSY 000431980 GASKET FLY END 000431990 GASKET FREE END 000510850 RING 0 5.28 X1.78 SS15 HV HP...
  • Page 35 Recommended spares IOH spares for TRC 1000 MN UG code : 072404019 Drg. /Part No. Description Qty. S.No. 000520130 STUD M12X60 C/CASE TO 70CYL SS 000520140 STUD M12X75 100CYL B/G FIXING 000906183 BOLT HEX M12X30 8.8 ZYP 5-8M 000948012 HEX. NUT M 12...
  • Page 36 INTER COOLER COMPLETE 070309690 AFTER COOLER COMPLETE 070310410 DISC COUPLING TRC1000MN UG A070047 C/FAN & FLG ASSY TRC1000MN Piston ring set dia 100 for TRC 1000 MN UG code : 072404039 Drg. /Part No. Description Qty. S.No. ---- RING TPC DIA100...
  • Page 37 Spare parts list...
  • Page 39 Package assy - TRC 1000 MN - UG (TPL No. : S 07096) Fig. No. Description Drg./Part No. TRC 1000 MN UG RAC UNIT ----- BASE 000221720 COOLING SYSTEM ----- DRIVE SYSTEM ----- FAN GUARD ASSY 070310400...
  • Page 41 RAC Unit assy - TRC 1000 MN - UG Drg. /Part No. Description Qty. S.No. 070301120 Crank shaft Assy (A070069) 020494550 Piston Assy Dia 100 000413120 Piston Assy Dia 60 000312040 Disc valve Dia 100 (A020042) 000313810 Disc valve Dia 60 (A070017) 000438600 Drain plug A020030...
  • Page 43 RAC Unit assy - TRC 1000 MN - UG Drg. /Part No. Description Qty. S.No. 000519210 Gasket Big DV Dia 100 000519220 Gasket small DV Dia 100 070309930 Head M/C Dia 100 Cylinder 000514550 Stud M12x54 070306140 Cylinder Dia 60 DV 000518830 Stud M12x70 000524060...
  • Page 45 Cooling system Fig. No. Description Drg./Part No. Drain valve 1/4" BSP, I/C,/A/C A020045 After cooler complete 070309690 Holder RH I/C 000445950 Cooler holder with clamp 000445940 Inter cooler complete 070309680 LP outlet manifold 070309770 Gasket dia 90 head 070408090 Pipe I/C to HP 070408170 Gasket cooler pipe 07040544A...
  • Page 46 Fig. 3 Motor & fan assy...
  • Page 47 Motor & fan assy Fig. No. Description Drg./Part No. C/Fan & FLG assy A 07 0047 TRC 1000 MN 14 HP Motor 10*490369 Disc coupling 07 03 1041 0 Bolt, Hex M8 x 35 00 09 0611 8 Nut, Hex M8 00 09 4800 8...
  • Page 48 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)
  • Page 49 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 Taper plain compression ring ----- Stepped compression ring ----- Slotted oil control ring ----- Piston with G.Pin (Including 4,5 & 6) 00 04 7777 0 Piston dia.
  • Page 50 Fig. 6 Air filter assembly (Part No. 070309310)
  • Page 51 Fig. 5 Air filter assembly (07 03 0931 0) Fig. No. Description Qty. Drg./Part No. Rubber bush 070408750 Bottom cover ----- Filter Element 070407510 Sealing ring 070408760 Top cover -----...
  • Page 52 Fig. 6 Drain valve assy Fig. 8 Breather valve assy 1/4” BSP...
  • Page 53 Drain valve assy - 1/4” BSP - A020045 Fig. No. Description Qty. Drg./Part No. Housing ----- Cone seat ----- Valve seat 00 05 1993 0 Breather valve assy - A020030 Fig. No. Description Qty. Drg./Part No. Breather bottom ----- Breather valve 00 05 1006 0 Breather top -----...
  • Page 54 Disc valve assembly - Dia 100 Disc valve assembly - Dia 60...
  • Page 55 Disc valve assembly Disc valve assembly - Dia 100 Fig. No. Description Qty. ELGI Part No. DISC VALVE ASSEMBLY A 02 0042 DIA.100 (00 03 1204 0) Bottom seat plate ----- Stud M10 x 35 00 05 1915 0 Bottom plate for suction valve...
  • Page 61 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...
  • Page 62 © 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...
  • Page 65 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 &...
  • Page 66 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...
  • Page 67 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...
  • Page 68 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.
  • Page 69 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.
  • Page 70 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.
  • Page 71 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.
  • Page 72 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.
  • Page 73 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.
  • Page 74 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...
  • Page 75 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...

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