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

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 removal of a guard or safety features, be sure to replace the guards or safety feature before resuming operation of the compressor.

Always wear eye protection

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

Protect yourself against hot spot

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

Disconnect the compressor

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

Avoid unintentional starting

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

Store compressor properly

When not in use, the compressor should be stored in dry place, remove the electrical supply. Keep out of 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.

2

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 expertise to perform the repair operations correctly.

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

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

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.

3

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

A v o i d e l e c t r i c a l s h o c k h a z a r d . N e v e r u s e t h i s 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.

4

Technical Specifications

01 Model TRC 1000 MN UG

02 Type Reciprocating, Air cooled, ‘W’ type

and oil Splash lubricated

03

04

05

Working pressure

Displacement

Free air delivery kgf/cm 2 m 3 /h cfm lpm m 3 /h cfm lpm

10.5

78.48

46.19

1308

60.00

35.32

1000

06 Cylinder size & stroke

07

08

09

10

11

12 length

No. of stages

Compressor speed

Type of valve

Direction of rotation

Type of drive

Crankcase oil capacity mm

No.

rpm ml

13 Recommended oil

14 Nett weight

15 Overall dimensions

LxBxH

16 Safety valve on intercooler

Opening pressure kg mm kg/cm 2

100 x 60 x 100 : 85mm

2

980

Disc valve

Anticlockwise as viewed from non-driving end

Directly coupled with motor by disc coupling

Min. 650

Max. 1880

Servo press 150

450±10

1135 x 770 x 925

6

5

Technical Specifications

17 Coupling

Model

18 Suction filter a. Type

19 Motor a. Make b. Type c. Power d. Voltage e. Rated current f. No. of phases g. Frequency h. Enclosure g. Insulation h. Speed i. Rating j. Frame Size k. Recommended grease

L. Weight

Unit

20 Shaft & Bore size a. Motor shaft b. Coupling bore(motor side) c. Fan flange bore d.Compressor shaft e. Coupling bore(Comp.side) f. Bore finish

Unit mm mm mm mm mm

Disc type coupling

Dry type

Make

HP

Amp

CROMPTON / BHARAT BIJILI

TEFC, Sqiurrel cage induction

14

Base voltage 415V

(290-500v)

24

Hz rpm kg

Three phase conn. in star

50

IP 54

Class H

975 / 970

Continuous

180L / 180 L

Lithium base GR.3

SERVOGEM GR.3

200 / 205

Ø

Ø

Ø

Ø

Ø

48

48

48

43

43

Ground

+0.018

+0.002

+0.021

+0.000

-0.005

-0.016

-0.03

-0.04

-0.030

-0.050

6

Technical Specifications

Cylinder, Piston and Piston ring size

SI.No

1

2

Cylinder bore

Piston

Description mm mm

3

4

Gudgeon pin size

Clearance in cylinder Normal mm

Max mm

5 No. of plain compression rings

8

9

6

7

10

No. of stepped compression rings

No. of slotted oil control rings

No. of perma seal ring

No. of oil control three piece ring

Permissible piston rings ,

Permissible stepped rings ,

Permissible oil control rings , butt clearence Normal mm

Max.

mm

11 Permisible perma seal piston ring butt clearance

Permisible perma seal oil control ring clearance

12 permissible piston rings side play in groove Normal

Max.

mm mm

13.

Connecting rod small end needle roller bearing internal diameter mm

14.

Clearence between piston

Crown and disc valve mm

--

--

2

2

LP

Dia 100

+0.01

0.00

Dia 99.835 -

Dia 99.855

0.000

Dia 20 -0.005

0.15 - 0.16

0.25

1

0.08 to 0.25

0.40

0.06

0.25

0.04 to 0.08

0.12

20

1.4 to 1.6

--

2

2

--

--

HP

Dia 60

+0.01

0.00

Dia 59.941 -

Dia 59.915

Dia 18

0.000

-0.005

0.06 - 0.09

0.20

--

--

0.09

--

0.024 to 0.074

0.1

18

1.4 to 1.6

7

8

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.

9

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

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

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

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

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.

4

5

6

1

2

3

Maintenance Schedule -Comparison between TRC1000MN and TRC1000MNUG

SI

No.

Maintenance Practice

Maintenance schedule for

TRC 1000 MN

Maintenance schedule for

TRC 1000 MN UG

7

8

Check oil level and top up, if required

Greasing of coupling

Intake air filter- Inspect element, clean if dirty

Inlet & Discharge Valve cleaning & Inspection

Drain and refill oil

Replace the Piston Rings, if required

Replace all the Pistons, if required

Replace all the Cylinders, if required

45 Days

45 Days

90 Days

90 Days

90 Days

540 Days

(AOH -M18)

720 Days

(IOH -M24)

720 Days

(IOH -M24)

90 Days

Eliminated

180 Days

180 Days

180 Days

720 Days

(AOH-M24)

1080 Days

(IOH-M36)

1080 Days

(IOH-M36)

14

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

Repairs

Crankshaft assembly

Remove 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 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

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

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

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).

Hub compressor side

Disc pack Spacer

Disc pack

Hex bolt

Hex nut

Over load washer

19

Hub motor side

20

21

Disc coupling model assy instructions

COMPRESSOR

22

Torque chart

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

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

Model : TRC 1000MN - UG

SI.

No.

Location Thread size

Tightening torque Values are in N-m

End cover Free-end

End cover Fly-end

Crankcase to base

Motor to base

Crankcase to Cylinder

Cylinder to head

Pipe flange joints

Pipe flange joints

Disc coupling bolt

Drain plug

Dipstick

M8

M8

M12

M12

M12

M12

M12

M10

M8

3/8" BSP

½" BSP

30 N-m

30 N-m

50 N-m

50 N-m

50 N-m

50 N-m

50 N-m

30 N-m

33 N-m

30 N-m

35 N-m

23

Troubleshooting

Problem : Pressure build time excessive

Check

Suction air filter is clogged

ä

Remedy

Increase frequency of cleaning.

Pipe line leaking

ä

Increase frequency with more level in periodic check of oil.

Disc valves defective .

Carbon deposits too much

ä

Remove cylinder head and the disc valves, decarbonisation should be done.

Piston rings worn out

ä

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 is not functioning properly.

ä

Check the safety valve components for correctness & reset to recommended rating.

Problem : LP safety valve operates during compressor running

Check

Disc valve in the HP cylinder not functioning

properly.

Remedy

ä

Check the disc valve components, clean the dust if any and rectify the defect.

24

Troubleshooting

Problem : Abnormal noise and knocking of compressor

Check

Connecting rod &

Crankshaft assembly defective.

ä

Remedy crankshaft assembly should be reconditioned

Journal bearings are worm out.

ä

Change the bearings.

Gudgeon pin loose in piston

Disc valve is defective

ä Change piston and check for lubrication

ä

Check and if necessary replace the parts required.

Coupling is wornout

(Loose on the bore)

ä Check the coupling hubs & change if required.

Key of the compressor and motor loose.

ä

Replace with correct size key.

Problem : Compressor overheating

Check

Dirty oil Oil, level low

Remedy

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

ä

Open, clean and refit after checking.

Breather not working

25

Troubleshooting

Problem : Compressor seizure / piston scoring

Check Remedy

Insufficient lubrication or oil become too thick

ä Maintain correct oil level or change the oil.

Incorrect direction of rotation

ä

Correct the direction of rotation.

Insufficient clearence between cylinder, piston and rings (if fitted new)

ä

Correct as per recommendation.

Maintain clearence as per chart given.

Problem : Oil carry over in compressor air

Check

Oil leaking through piston ring gap and piston

ä

Remedy

Remove the piston, cylinder and check the bore clearence. For recommendation, please refer technical data.

Oil viscosity to low.

ä

Change to recommended grade.

Problem : Oil leak through breather

Check

Breather valve not working, Piston ring stuck in grooves or broken.

Remedy

ä

Open, clean and refit the breather.

Loosen the piston rings. If broken, change the rings as a set.

Piston to cylinder excessive.

ä

Check and change.

26

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

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 160 O C. 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

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 O C which is the maximum allowable temperature for class F insulation.

29

Standard and special tools

10

9

1 2 3 4

5 6 7

Fig.

No

Description

1 Ring gauge for 60 dia piston assembly

(Ring Inserting tool)

2 Ring gauge for 100 dia piston assembly

(Ring Inserting tool)

3 Pusher with nut for compressor side

4 Pusher with nut for motor side

Part No

000415230

000415240

000427400

000427420

5 Spacer flange for pusher common for compressor and motor side

6 Coupling removal tool Motor side and compressor side

7 Tool coupling axial measuring

8 Tool coupling dial holder

9 Radial dial gauge

10 Angular dial gauge

000427410

070312130

070312140

070312150

M008992184

M000057186

30

8

Standard and special tools

SL. No

8

9

6

7

10

11

12

13

3

4

5

1

2

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

Pipe wrench 9”

Screw driver 6”

31

Recommended spares

12

13

14

15

16

17

18

19

20

3

4

5

1

2

8

9

6

7

10

11

AOH spares for TRC 1000 MN UG code : 072404009

S.No.

Description

00041004A

00041004B

072404039

072404049

000435920

000519930

000415160

000415170

000415180

Drg. /Part No.

CONSISTING OF

000431990

000431980

000524060

000524070

000519210

000519220

00041004C

000430050

000510850

000424060

000521960

Qty.

GASKET FREE END

GASKET FLY END

PKG BIG DIA 60 D/V TRC I000MN 2

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

GASKET BIG CYL TO D/V DIA100 4

1

1

GASKET SMALL D/V TO CYL HEAD

GASKET 0.8 C/CASE TO CYL TS05

PKG DS ASSY TRC1000MN/1000B

RING O 5.28X1.78 SS15 HV HP

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

RING PKG 21X25X2 (DIPSTICK)

1

2

1

1

2

3

GASKET 0.25C/CASE TO CYL TS05

GASKET 0.4 C/CASE TO CYL TS05

PISTON RING SET DIA 100 MN UG

PISTON RING SET DIA 60 MN UG

VALVE SEAT SN

VALVE SEAT DRAIN VALVE

BOTTOM PLATE

SUCTION VALVE SPRING

SUCTION VALVE PLATE

2

1

1

3

3

2

2

2

2

32

Recommended spares

AOH spares for TRC 1000 MN UG code : 072404009

30

31

32

33

24

25

26

27

28

29

S.No.

21

22

23

Drg. /Part No.

000415190

000415200

000424350

000424340

000424330

000424360

000510060

000420350

000424330

000917218

000917220

070408090

07040544A

Description

DELIVERY VALVE PLATE

DELIVERY VALVE SPRING

VALVE SPRING SUC TRC 1000MN

VALVE PLATE SUCTION TRC 2000

VALVE PL DEL TRC1000MN

VALVE SPRING DEL TRC I000MN

VALVE BREATHER

SEAL OIL B45X60X12.5

VALVE PL DELIVERY

CIRCLIP INTERNAL 18 MM

CIRCLIP INTERNAL 20 MM

GASKET LP OUTLET

GASKET FLANGE

2

1

1

1

1

1

Qty.

2

4

2

2

4

3

5

33

Recommended spares

IOH spares for TRC 1000 MN UG code : 072404019

5

6

7

8

3

4

S.No.

Drg. /Part No.

CONSISTING OF

1

2

000424060

000430050

Description

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

PACKING DS ASSY

000431980

000431990

000510850

000519210

000519220

000521830

GASKET FLY END

GASKET FREE END

RING 0 5.28 X1.78 SS15 HV HP

GASKET BIG CYL TO D/V DIA100

GASKET SMALL D/V TO CYL HEAD

RING PKG 33.5X38X3

9 000521930

10 000521960

11 000524060

12 000524070

13 00041004C

14 00041004A

15 00041004B

16 000420350

17 000466780

18 070405060

19 000477770

20 000511230

21 000514550

22 000514560

23 000518830

Qty.

RING PKG CONNECTOR HSG TO ERMETO 3

RING PKG 21X25X2 (DIPSTICK)

PKG BIG DIA 60 D/V TRC I000MN

PKG SMALL DIA 6O D/V TRC 1000MN

GASKET 0.8 C/CASE TO CYL TS05

GASKET 0.25C/CASE TO CYL TS05

GASKET 0.4 C/CASE TO CYL TS05

SEAL OIL B45X60X12.5 SS07/10

DISC END TRC 1000MN

PISTON AND GP DIA60 RR15070

PISTON & GP DIA100 SSO7/10

NIPPLE HEX 3/4"X3/4" BSPX40

STUD M12X54 60 CYL

STUD M12X45 C/CASE TO 50CYL

STUD M12X70 SS 02/03/05 TSO2/03

1

3

1

1

1

3

3

2

1

6

8

1

2

1

2

4

2

3

1

1

1

1

34

Recommended spares

IOH spares for TRC 1000 MN UG code : 072404019

S.No.

Drg. /Part No.

25 000520130

Description

STUD M12X60 C/CASE TO 70CYL SS

26 000520140

27 000906183

STUD M12X75 100CYL B/G FIXING

BOLT HEX M12X30 8.8 ZYP 5-8M

28 000948012

29 000996112

30 072404039

31 072404049

32 000917218

33 000917220

HEX. NUT M 12

SPRING WAHSER M12

PISTON RING SET DIA 100 MN UG

PISTON RING SET DIA 60 MN UG

CIRCLIP INTERNAL 18 MM

CIRCLIP INTERNAL 20 MM

34 070308440

35 070306140

36 070408170

37 070408200

38 070408180

39 A020045

40 070309310

41 A070075

42 A020030

43 A020042

44 A070017

45 A070025

46 070408090

47 07040544A

CYLINDER DIA 100 M/C TRC1000BS

CYL DIA60 D/V M/C RR14100

PIPE I/C TO HP

PIPE HP CYL TO AFTER COOLER

DELIVERY PIPE ASSLY

VALVE ASSY DRAIN 1/4" BSP MN

AIR FILTER ASSY, TRC1000MN UG

DIPSTICK WITH CHAIN TRC 1000MN

VALVE ASSY BREATHER ALUMINUM

D/V ASSY DIA 100

VALVE ASSY DISC DIA 60 TRC 1000MN

VALVE ASSY SAFETY 3/8"BSP MN

GASKET LP OUTLET

GASKET FLANGE

2

1

1

2

1

1

2

1

1

1

3

5

1

1

2

1

2

4

24

24

Qty.

4

5

1

35

Recommended spares

POH spares for TRC 1000 MN UG code : 072404029

5

6

3

4

S.No.

Drg. /Part No.

CONSISTING OF

1

2

072404019

A070069

Description

KIT -IOH SPARES TRC1000MNUG

CRANK SHAFT ASSY & BRG

070309680

070309690

070310410

A070047

INTER COOLER COMPLETE

AFTER COOLER COMPLETE

DISC COUPLING TRC1000MN UG

C/FAN & FLG ASSY TRC1000MN

Qty.

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

S.No.

1

Drg. /Part No.

----

2

3

----

----

Description

RING TPC DIA100

RING SC DIA100

RING SOC DIA100

Qty.

1

2

2

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

S.No.

1

Drg. /Part No.

----

2 ----

Description

RING TF PERMASEAL DIA60 RR1507

RING OIL DIA60 RR15070

Qty.

2

2

1

1

1

1

1

36

Spare parts list

37

38

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

Fig. No.

1

2

3

4

5

Description

TRC 1000 MN UG RAC UNIT

BASE

COOLING SYSTEM

DRIVE SYSTEM

FAN GUARD ASSY

Qty

1

1

1

1

1

Drg./Part No.

-----

000221720

-----

-----

070310400

39

40

RAC Unit assy - TRC 1000 MN - UG

Drg. /Part No.

070301120

020494550

000413120

000312040

000313810

000438600

A020030

070309960

000431990

000318090

000996108

000906115

000420350

000431980

000317770

000521860

000514560

00041004C

000906183

070308440

000996112

000948012

000520130

000520140

14

15

16

17

18

19

20

21

22

23

24

8

9

10

11

12

13

5

6

7

S.No.

1

2

3

4

Description

Crank shaft Assy (A070069)

Piston Assy Dia 100

Piston Assy Dia 60

Disc valve Dia 100 (A020042)

Disc valve Dia 60 (A070017)

Drain plug

Breather

C/Case M/C

Gasket free end cover

Cover free end

Spring washer M8

Bolt Hex M8x20

Oil seal

Gasket Fly end cover

Cover Fly end

Packing ring 17x22x2

Stud M12x45

Gasket C/Case to Cylinder

Bolt Hex M12x30

Cylinder Dia 100

Spring washer M12

Hex Nut M12

Stud M12x60

Stud M12x75

1

8

3

1

1

4

2

30

24

2

6

1

14

14

1

1

1

Qty.

1

2

1

2

1

1

1

41

42

RAC Unit assy - TRC 1000 MN - UG

Drg. /Part No.

000519210

000519220

070309930

000514550

070306140

000518830

000524060

000524070

000917218

070307830

000521960

070400690

000466020

00041361B

000436650

000466660

000903361

070408160

070404970

070408150

070309310

38

39

40

41

42

32

33

34

35

36

37

43

44

45

S.No.

25

26

27

28

29

30

31

Description

Gasket Big DV Dia 100

Gasket small DV Dia 100

Head M/C Dia 100 Cylinder

Stud M12x54

Cylinder Dia 60 DV

Stud M12x70

Gasket Big DV Dia 60

Gasket small DV Dia 60

Circlip Internal

Cylinder Head Dia 60 DV

Packing ring 21x25x2

Dipstick with chain

Lock Nut 1/2" BSP

Pipe breather 1/2" BSP

Reducer 1"x1/2" BSP

Key 12x8x60

BRG 6310

Suction pipe LH

Gasket Filter

Suction pipe RH

Filter Assy

1

2

1

1

1

1

1

1

1

1

2

2

1

2

Qty.

4

2

2

7

1

1

2

43

44

Cooling system

14

15

16

17

18

9

10

11

12

13

22

23

24

19

20

21

Fig. No.

1

2

3

4

5

6

7

8

Description

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

After cooler complete

Holder RH I/C

Cooler holder with clamp

Inter cooler complete

LP outlet manifold

Gasket dia 90 head

Pipe I/C to HP

Gasket cooler pipe

Bolt hex M12 x 45

Pipe HP cyl to A/C

Delivery pipe assy

Safety valve 3/8" BSP

Bolt hex M10 x 30

Spring washer M10

Bolt hex M10 x 45

Bolt hex M10 x25

Bolt hex M12 x 30

Spring washer M12

Bolt hex M10 x 40

Flange with Ebow

Gasket

Nut hex M12

Nut hex M10

Drg./Part No.

A020045

070309690

000445950

000445940

070309680

070309770

070408090

070408170

07040544A

000906186

070408200

070408180

A070025

000906145

000996110

000906148

000906144

000906183

000996112

000906148

000480920

000424060

000948012

000948010

14

29

8

2

4

5

2

1

1

1

1

2

6

4

4

1

2

1

1

3

1

Qty

2

1

1

45

Fig. 3 Motor & fan assy

46

Motor & fan assy

Fig. No.

1

2

3

4

5

Description

C/Fan & FLG assy

TRC 1000 MN 14 HP Motor

Disc coupling

Bolt, Hex M8 x 35

Nut, Hex M8

Drg./Part No.

A 07 0047

10*490369

07 03 1041 0

00 09 0611 8

00 09 4800 8

47

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

Piston assy - dia. 100

Fig. No.

1

2

3

4

5

6

Description Qty.

PISTON ASSY. DIA. 100 (Incl.No.1 to 5) 1

Taper plain compression ring 1

Stepped compression ring

Slotted oil control ring

2

2

Piston with G.Pin (Including 4,5 & 6)

Piston dia. 100

Gudgeon pin dia. 20

Circlip B20

Kit, Ring set (Incl No. 1,2,3)

1

1

1

2

2

Drg./Part No.

00 04 1311 0

-----

-----

-----

00 04 7777 0

-----

00 05 1419 0

00 09 1722 0

07 24 0403 9

Piston assy - dia. 60

Fig. No.

3

4

5

1

2

Description Qty.

PISTON ASSY DIA 60 (Incl.No.1 to 4) 1

Ring perma-seal 2

Ring oil 3-piece

Piston with G-pin (Including 3,4&5)

Piston dia 60

2

1

1

Gudgeon pin Dia 18

Circlip 18mm

Kit, Ring set (Incl No. 1,2,)

1

2

2

Drg./Part No.

07 04 0508 0

-----

-----

07 04 0506 0

-----

00 05 1418 0

00 09 1721 8

07 24 0404 9

49

5

4

3

2

1

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

50

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

Fig. No.

1

2

3

4

5

Description

Rubber bush

Bottom cover

Filter Element

Sealing ring

Top cover

Qty.

1

1

1

1

1

Drg./Part No.

070408750

-----

070407510

070408760

-----

51

Fig. 6 Drain valve assy

1/4” BSP

Fig. 8 Breather valve assy

52

Drain valve assy - 1/4” BSP - A020045

Fig. No.

1

2

3

Description

Housing

Cone seat

Valve seat

Qty.

1

1

1

Drg./Part No.

-----

-----

00 05 1993 0

Breather valve assy - A020030

Fig. No.

1

2

3

4

Description

Breather bottom

Breather valve

Breather top

C.S. Screw M6 x 9

Qty.

1

1

1

2

Drg./Part No.

-----

00 05 1006 0

-----

00 05 2069 0

53

Disc valve assembly - Dia 100

Disc valve assembly - Dia 60

54

5

4

7

6

3

9

8

2

1

8

7

6

5

4

3

2

1

11

10

9

Disc valve assembly

7

8

5

6

3

4

1

2

9

10

11

Disc valve assembly - Dia 100

Fig. No.

Description

DISC VALVE ASSEMBLY

DIA.100

Bottom seat plate

Stud M10 x 35

Bottom plate for suction valve

Suction valve spring

Suction valve plate

Delivery valve plate

Delivery valve spring

Pin

Top seat plate

Spring washer M10

Hex. nut M10 1

(Kit, Disc valve Dia 100 (Consist of items 5,6,7&8) 1

1

1

2

1

1

1

1

1

1

1

Qty.

ELGI Part No.

A 02 0042

1 (00 03 1204 0)

-----

00 05 1915 0

00 04 1516 0

00 04 1517 0

00 04 1518 0

00 04 1519 0

00 04 1520 0

00 05 1916 0

-----

00 09 9611 0

00 09 4801 0

02 24 0098 9

Disc valve assembly - Dia 60

Fig. No.

Description

DISC VALVE ASSEMBLY

DIA.60

6

7

4

5

8

9

1

2

3

Qty.

1

Bottom seat plate

Stud M8 x 32

Suction valve spring

Suction valve plate

Delivery valve plate

Delivery valve spring

Top seat plate

Spring washer M8 1

Hex. nut M8 1

(Kit, Disc valve Dia 60 (Consist of items 3,4,5 &6) 1

1

1

2

2

1

1

1

ELGI Part No.

A 07 0017

(00 03 1381 0)

-----

00 05 2259 0

00 04 2435 0

00 04 2434 0

00 04 2433 0

00 04 2436 0

-----

00 09 9610 8

00 09 4800 8

07 24 0098 9

55

Notes

56

Notes

57

Notes

58

Notes

59

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

©

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 : [email protected]

[email protected]

www.elgi.com

64

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

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

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

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

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.

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.

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

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.

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.

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.

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 : Ta m i l n a d u , K a r n a t a k a , K e r a l a , P o n d i c h e r r y,

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 :

[email protected]

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

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