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List of Contents

iii

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

Содержание TRC 1000 MN UG

Страница 1: ...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 All...

Страница 2: ...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 th...

Страница 3: ...rized 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...

Страница 4: ...r 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...

Страница 5: ...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...

Страница 6: ...es 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...

Страница 7: ...s 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...

Страница 8: ...8 General view of the compressor...

Страница 9: ...ide 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 lubr...

Страница 10: ...ions 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...

Страница 11: ...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 a...

Страница 12: ...agents to clean the interior when changing oil NOTE Lubricating oil change should be carried out during Recommended maintenance schedule Recommended lubricating oil Servo press 150 WARNING During trip...

Страница 13: ...ted 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 f...

Страница 14: ...ny 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...

Страница 15: ...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...

Страница 16: ...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 s...

Страница 17: ...s 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...

Страница 18: ...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 b...

Страница 19: ...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 300 TIR as such please follow above procedure till the re...

Страница 20: ...ust 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 to 0 26 3 To adjust the angular shift it s require...

Страница 21: ...adial shift 1 2 TIR add shims at rear foot Radial sample readings Angular sample readings Motor position as per radial reading Remarks add shim here add shim here 1 To adjust radial shift 2 0 TIR add...

Страница 22: ...sc coupling model assy instructions Radial sample readings Angular sample readings Motor position as per radial reading Remarks 0 1 add shim here FAN MOTOR COMPRESSOR COUPLING DIAL GAUGE TO MEASURE AN...

Страница 23: ...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 M...

Страница 24: ...n should be done Piston rings worn out Check the ring gap if required change the rings Problem Low pressure safety valve operates though the specified pressure is not reached Check Remedy safety valve...

Страница 25: ...ange piston and check for lubrication Disc valve is defective Coupling is wornout Loose on the bore Key of the compressor and motor loose Check and if necessary replace the parts required Check the co...

Страница 26: ...ain clearence as per chart given Problem Oil carry over in compressor air Check Remedy Oil leaking through piston ring gap and piston Remove the piston cylinder and check the bore clearence For recomm...

Страница 27: ...eservation 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 D...

Страница 28: ...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...

Страница 29: ...s 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...

Страница 30: ...ut 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...

Страница 31: ...x 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 wrenc...

Страница 32: ...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 25...

Страница 33: ...0424340 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 V...

Страница 34: ...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...

Страница 35: ...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 D...

Страница 36: ...60 RR1507 2 2 RING OIL DIA60 RR15070 2 S No Description Qty Drg Part No S No Description Qty Drg Part No POH spares for TRC 1000 MN UG code 072404029 CONSISTING OF 1 072404019 KIT IOH SPARES TRC1000MN...

Страница 37: ...37 Spare parts list...

Страница 38: ...38 Fig 1 Package assy TRC 1000 MN UG TPL No S 07096...

Страница 39: ...39 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...

Страница 40: ...40 Fig 2 Unit assy TRC 1000 MN UG...

Страница 41: ...e 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...

Страница 42: ...42 Fig 2 Unit assy TRC 1000 MN UG...

Страница 43: ...524070 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...

Страница 44: ...44 Fig 3 Cooling System...

Страница 45: ...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 1...

Страница 46: ...46 Fig 3 Motor fan assy...

Страница 47: ...47 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...

Страница 48: ...Piston Assembly Dia 60 Part No 07 04 0508 0 Rail opening spacer opening should be at 90 Deg difference approximately Keep the PIP mark in top during assy Fig 4 Piston Assembly Dia 100 Part No 00 04 1...

Страница 49: ...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 6...

Страница 50: ...50 Fig 6 Air filter assembly Part No 070309310 1 2 5 4 3...

Страница 51: ...51 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...

Страница 52: ...52 Fig 8 Breather valve assy Fig 6 Drain valve assy 1 4 BSP...

Страница 53: ...scription 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 Bre...

Страница 54: ...54 Disc valve assembly Dia 60 Disc valve assembly Dia 100 11 10 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 8 7...

Страница 55: ...9 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 100 Disc valve assembly Fig No Description Qty ELGI Part No DISC VALVE ASS...

Страница 56: ...56 Notes...

Страница 57: ...57 Notes...

Страница 58: ...58 Notes...

Страница 59: ...59 Notes...

Страница 60: ...RECORD Date of inspection Date of completion of service Scheduled date of next inspection and service Results of inspection and outline of service Oil change Others Inspected or serviced by Air valve...

Страница 61: ...ELECTRIC POWERED RECIPROCATING AIR COMPRESSORS OPERATION AND MAINTENANCE MANUAL PARTS MANUAL BASE MOUNTED MODEL TRC 1000 MN UG for Electric Locomotive 2 Stage 3 Cylinder...

Страница 62: ...mbatore 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 Part Document No Revision Status R...

Страница 63: ......

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Страница 65: ...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 ass...

Страница 66: ...ER 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...

Страница 67: ...ss 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 detai...

Страница 68: ...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 Pleas...

Страница 69: ...es 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 preci...

Страница 70: ...n 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 late...

Страница 71: ...ned 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 rec...

Страница 72: ...ts being made constantly and continuously the illustrations and descriptions on this manual are not binding Death or serious bodily injury could result from improper or unsafe use of compressor To avo...

Страница 73: ...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...

Страница 74: ...unicated 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...

Страница 75: ...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 U...

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Страница 80: ...CE RECORD Date of inspection Date of completion of service Scheduled date of next inspection and service Results of inspection and outline of service Oil change Others Inspected or serviced by Air val...

Страница 81: ...81...

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