RECIPROCATING

AIR COMPRESSOR
FOR DMU/ DIESEL
SHUNTING LOCOMOTIVE

2 S T A G E 3 C Y L I N D E R
TRC 1000 B

OPERATION, MAINTENANCE MANUAL &

PARTS LIST

Fab. No................................................................
ELGI EQUIPMENTS LIMITED
Trichy Road, Singanallur,
Coimbatore - 641 005, INDIA
Phone : +91-422 - 2589555
Fax : +91-422 - 2573697
E-Mail : info@elgi.com

Part / Document No. 07 90 03 010

Revision status : R00 - Oct 2000

R01 - Nov 2004
R02 - Dec 2005
R03 - Jan 2007
R03 - Mar 2008 - Reprint
R03 - Sep 2009 - Reprint
R03 - Jan 2011 - Reprint
R04 - Aug 2012
R04 - Jun 2013 - Reprint

Printed in India

Price : INR 500

Compiled By :

Research and development department

C O N T E N T S

Description Page No.

I List of contents .............................................................................. iii

II Machine identification and sale record ............................................... v
III Message from the Managing Director .................................................. vi
IV About Elgi ........................................................................................ vii
V Introduction ..................................................................................... viii
VI User's commitment............................................................................. ix
VII Notes & Warnings............................................................................... x
VIII Using this operation & Maintenance manual.......................................... xi
IX Customer Care System (CCS) xii
X Do's and Dont's................................................................................. 1
XI Safety Instructions ............................................................................ 2
1. Technical Data ................................................................................. 5
2. Recommended Lubricants / Manufacturers ...................................... 6
3. System Operation ............................................................................ 6
4. Function of Various Systems ............................................................ 7
5. Safety and interlocking Device ......................................................... 8
6. Installation ....................................................................................... 9
7. Operation ........................................................................................ 11
8. Maintenance Schedule ..................................................................... 13
9. Repairs ............................................................................................ 15
10. Standard and Special Tools .............................................................. 18
11. Trouble Shooting .............................................................................. 19
12. Recommended Spares ..................................................................... 21
13. Parts List ......................................................................................... 24
13-1. Reciprocating Air Compressor Unit Package .................................... 25
13-2. Piston Assembly, Dia 100 ................................................................. 29
13-3. Piston Assembly, Dia 60 ................................................................. 29
13-4. Safety Valve Assembly 3/8" BSP ...................................................... 29
13-5. Filter Assembly, Oilbath, Air Inlet ..................................................... 31
13-6. Valve Assembly, Breather ................................................................. 31
13-7. Valve Assembly, Drain 1/4" BSP........................................................ 31
13-8. Disc. Valve Assembly, Dia. 100 ........................................................ 33
13-9. Disc. Valve Assembly, Dia. 60 .......................................................... 33
14. Notes .............................................................................................. 35

iii

3835
 iv

3835
 Machine Identification and Sale Record

Owner’s name : ______________________________

Address : ______________________________

Model : ______________________________

FAB No. : ______________________________

Year of manufacture : ______________________________

Motor : ___________________________kW

Capacity : ________________________m3/ min

Rated Pressure : _________________________bar g

Date of Delivery : ______________________________

Date of Commissioning : ______________________________

3835
Message from the Managing Director
Dear ELGI customer,

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

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

ELGI has designed your Horizon 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 Horizon compressor optimally. Please
familiarise yourself with all the information it contains.

I look forward to your continued satisfaction as a Horizon user. ELGI is honoured

to be your choice for all your compressed air needs.

Yours sincerely,

Jairam Varadaraj
Managing Director

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3835
 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 own ηV (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

3835
Introduction
We are confident ; the equipment you have purchased will give you satisfactory
service for its life. We thank you for giving us an opportunity to serve you with
our compressor.

Please check and ensure OPERATION AND MAINTENANCE MANUAL AND

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

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

This manual must be made available to the compressor operating personnel at

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

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3835
 Users' Commitment
Read and understand all of the operating instructions, safety precaution and
warnings in the instruction Manual before operating or maintaining this
compressor.

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

Basic safety precautions are outlined in the "SAFETY" section of this Instruction
Manual that has to be followed with utmost care to be taken 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.

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

1. MODEL

2. FAB NUMBER

3. YEAR OF MANUFACTURE

4. PART NAME

5. PART NUMBER

6. REQUIRED QUANTITY

ix

3835
Notes and Warnings
In case of any requirements of spares or service, please contact our nearest
branch office or distributors

Due to improvements being made constantly and continuously, the illustrations

and descriptions on this manual are not binding.

SAFETY
IMPORTANT SAFETY INSTRUCTIONS FOR USE OF THE COMPRESSOR

Death or serious bodily injury could result from improper or

! unsafe use of compressor. To avoid these risks, follow the

basic safety instructions.
WARNING

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

3835
 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 customized ELGI
compressor. Before you start using your compressor, go through this manual
thoroughly. It contains vital information on operation as well as useful tips that
will help you keep your compressor running as good as new year after year.

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

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

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

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3835
Customer Care System (CCS)
ELGI provides dedicated customer care and after-sales support through the
CCS, a computerised system developed in-house. The CCS aims to minimize
the time taken to resolve complaints.

Service Requests / Complaints

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

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

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 or
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, up to the level of the Managing Director. Thus the CCS
ensures that not only are customer complaints are logged, but they are also
attended on time every time.

Enquiries

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

products and spare parts. Details are noted, and basic information on product
specifications and usage are provided. The caller is informed whom to contact
for further discussions. The enquiry is passed on to a sales person at the Head
Office or the appropriate branch for follow-up.

The CCS Database

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

CCS—Working Hours

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

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3835
 Customer Care System (CCS)
Multi-lingual Capability

The coordinators 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 : 0422-2589 206/2589 241/2589 242/2589 243

2589 244/2589 245/ 97900 21100
Fax : 0422-2589 240

Email : ccs@elgi.com

Customer Satisfaction Survey

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

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3835
D o' s & D o n t' s

DO
Read the manual in detail and follow the instructions
Clean the air compressor package regularly
Keep the air filter clean
Use only genuine spares
Maintain correct oil level
Use only clean, recommended lubricants
Use proper tools
Attend immediately to anything unusual with the air Compressor
Maintain logbook to monitor operation of compressor
Attend repairs / service with qualified technicians only

DON'T
x Neglect the routine attention

x Allow any leakage in the system

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

x Meddle with any adjustments or settings

x Run the compressor without fan guard

x Use cleaning agents, when changing oil

x Do any repair work while the unit is running

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

3835
 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.

Project yourself against hot spot

Prevent body contact with grounded surface 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 card. All visitors should be kept
safely away from work area.

Operate compressor at the rate 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.

3835
Safety Instructions
Never 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 authorised 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 centre for
any repairs. Unauthorized modification may not only impair the compressor
performance but may also result in accident or injuiry to repair personnel who do
not have the required knowledge and technical expertise to perform the repair
operations correctly.
Turn off the starter stop button to be latched when the compressor
is not used
When the compressor is not used, disconnect it from the power source and open
the drain cock to discharge the compressed air from the air tank.

Dress properly
Not wear loose clothing or jewellary. 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.

Check damaged parts and air leak

Before further use of the compressor, in 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.

3835
 Safety Instructions
Handle compressor correctly
Operated the compressor according to the instructions provided herein. Never
allow thecompressor to be operated by children, individuals unfamiliar with its
operator or unauthorized personnel.

Keep all screws, bolts and covers tightly in place

Keep all screws, bolts and plates tightly mounted. Electrical connections to be
ensured for tightness. Check their conditions periodically.
Keep motor air vent clean
The motor air vent must be kept clean so that air can freely flow at all times.
Check for dust build-up frequently.
Drain tank
Drain tank daily or after 4 hours of use. Open drain fitting and tilt compressor
to empty accumulated water.

Electrical installation
This compressor motor and starter should properly grounded with correct size
copper wire to avoid electrical shock and damage to the equipment.
The correct rating of fuses to be provided at the incoming side of the Starter.
The correct rating of wires to be used for incoming connection and length of the
cable to be less than 5 mtrs.
Never take any loop lines from the compressor wiring.

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
WARNING environment where electric shock is possible.

3835
1 . TECHNICAL DATA

01 MODEL TRC 1000 B

02 Type Reciprocating, Air cooled, Splash
lubricated
03 Displacement lpm 1335
cfm 47.151
04 Free air delivery lpm 1000
cfm 35.32
2
05 Working pressure kgf/cm 8
06 Type of configuration W
07 Compression stage No. 2
08 Cylinders No. 3
09 Cylinder size & stroke mm 100 x 60 x 100 & 85
10 Type of piston rings Dia 100 Dia 60
a) Plain compression No. 2 1
b) Stepped compression No. 1 1
c) Slotted oil control No. 2 2
11 Type of valve disc valves LP & HP
(Suction & Delivery)
12 Volumetric Efficiency % 79
13 Compressor speed rpm 1000
14 Type of lubrication Splash
15 Type of cooling Air
16 Type of fan Forced draught
17 Oil fill capacity ml Max. 1350. Min 600
18 Grade of oil Servo Press 150
19 Direction of rotation Clockwise - viewed from non driving
end -STANDARD model.
Counter clockwise - viewed from non
driving end - SAN model
20 Safety valve set pressure kgf/cm2 5
21 Overall dimensions L x B x H mm 785 x 520 x 810
22 Net Weight kg 125
23 Mounting hole 350 x 114
24 No. of holes 4 holes. dia 14
25 DRIVE
a) Type of drive V belt
b) Type of groove & Qty. C & 2 No.
c) Compressor pulley mm OD 460.4, PCD 49

3835
2. R E C O M M E N D E D
L U B R I C A N T S /
MANUFACTURERS

Recommended Oil

Ambient ISO Bharat Indian Oil Chemoleums Bharat Shell

Temp 0C VG No. Petroleum

Bharat Servo Press Erato Shell

25 to 80 ISO 150 Compressor 150 150 HDC Corena

Oil 50 P150

3. SYSTEM OPERATION

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

3.2 Under normal conditions, the temperature in the first stage would be 195°C. This compressed air
enters into the inter-cooler, where the heat of compressor is considerably reduced. Intercooler has
safety valve which opens when the compressed air pressure exceeds the pre-determined set pressure.

3.3 This cooled compressed air then enters into the high pressure cylinder, where it is further
compressed to the required pressure as specified in the name plate. The discharge side of high
pressure cylinder head is provided with an ermeto joint to facilitate a take-off connection.

3835
4. FUNCTIONS OF
VARIOUS SYSTEM

4.1 Reciprocating Air Compressor Unit

The Reciprocating air compressor model TRC 1000 B is a two stage, three cylinder, oil splash
lubricated air cooled compressor. It consists of three cylinders arrange in a 'W' configurations on a
crankcase, with the low pressure (LP) cylinder at the sides and the high pressure (HP) cylinder in
the middle. The LP cylinder heads are provided with oil bath air filters at their suction sides. The
discharge sides of the LP cylinder heads are connected to an inter cooler pipe with deep finned
aluminium pipes for efficient cooling. Another aluminium pipe of similar design connects the inter
cooler with the suction side of the HP cylinder head. The outlet of the HP cylinder head is provided
with an ermeto to facilitate a take-off connection. At one end of the crankshaft a dynamically
balanced fly wheel cum pulley is fitted with a fan for cooling the cylinders and cylinder heads.

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

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

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. The crankshaft assembly is provided with an oil splasher for lubricating all moving parts
by splashing the oil in the crankcase.

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

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

In the oil bath inlet of the air filter, first the sucked air passes through the oil bath and then through
the wire mesh. While passing through the oil bath all dust particles in the air will be absorbed by
the oil and very few fine particles may mix with air. During its passage through wire mesh, the oil
particles with the dust particles will be separated from the air. So, the suction air will be dust free.

3835
4.2 Drive system

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

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

5. SAFETY AND INTER

LOCKING DEVICES

5.1 Safety Valve Dampening Pipe

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

3835
6. INSTALLATION

NOTE
Examine the package for transit damages.

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

6.1 Location of Compressor

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

NOTE
Never install the compressor near the boiler, furnace, in an enclosed
compartment or at any place where the atmospheric air is hot and dirty.

6.2 Ventilation and Cooling

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

6.3 Installation

After selecting a suitable location, install the unit properly. Refer dimensional drawing of the
compressor unit package shown in this manual (Page No.25)

6.4 Oil level Check

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

Oil fill capacity : Min. 600 ml

: Max. 1350 ml

3835
 WARNING
Before starting the units, fill the crank case with correct grade and proper
quantity of oil since oil is drained completely prior to shipping

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

6.5 Belt Tension

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

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

6.6 Direction of the Compressor

After the unit installation, it is necessary to check the direction of the compressor rotation. Start
the unit momentarily and observe the direction of rotation of the compressor. The direction of
rotation should be clockwise when viewed from non driving end. A direction of rotation 'DECAL'
(Name Plate) is located on the crankcase to indicate proper compressor rotation.

10

3835
7. O P E R A T I O N

7.1 General

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

7.2 Purpose of Controls

No. Controlor indicator Purpose

1. Pressure gauge Continuously monitors air receiver / delivery pipe

pressure at various load and unload conditions.

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

crankcase. Check oil level only when the machine is
shutdown. Do not overfill.

3. Safety valve Dampening pipe Set to open intercooler air pressure to atmosphere if
pressure exceeds 130% of the intermediate pressure of
the compressor.

4. Breather Maintains partial Vacuum inside the crankcase to

facilitate better lubrication.

7.3 Intial Start-up Procedure

Read the proceeding pages thoroughly.
Ensure all preparations and checks described in the chapter installation have been taken care of.
Fill the recommended grade of oil in the crankcase to the required level.

NOTE
Recommended Oil Servo Press 150 or equivalent.

Ensure proper belt tension. Too much tension will induce an excessive load on motor and
compressor bearings.
Check that the compressor rotates freely by hand and there are not mechanical obstructions.
Open the shut off valve of service line slightly.
Check all the points in Electrical System.

11

3835
7.4 Checks During Compressor Operation
Check whether the compressor is running smoothly and the running sound is normal.

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

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

7.5 Subsequent Start Up Procedure

On subsequent start up, check the proper oil level is visible in the dipstick and simply start the engine.
To shut off the machine, stop the engine.

12

3835
8. MAINTENANCE
S C H E D U L E

8.1 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 under mentioned
schedule.

IMPORTANT
Lubricating oil change should be carried out during every 60 days
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.

8.2 During trip schedule - 30 Days

1. Clean the compressor thoroughly.

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

8.3 During trip schedule - 60 Days

Check the compressor for satisfactory operation which include.

1. Cleanliness of the compressor.
2. Operational noise and vibration.
3. Tightness of mounting bolts and other fasteners.
4. Air leaks at the pipe joints and safety valve.
5. Clean the suction filters thoroughly and renew the oil to the correct level.
6. Check the suction and discharge operations and general performance of the compression.

8.4 During trip schedule - 90 Days

1. All check points indicated in above schedule to be carried out.

2. Breather valve should be dismantled, cleaned and checked for perfect seating of the valve.
3. Check the safety valve setting.

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3835
8.5 During trip schedule - 180 Days

1. All check points indicated under 60 days schedule to be carried out.

2. Remove all the disc valve 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. as detailed below.
Diamantle the disc valves, check the spring, 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 replace. All the parts should be decarbonised
and thoroughly cleaned in kerosene. Reassemble the valve and assemble it to the cylinder with
new packings.
3. All the pipe lines should be checked for leaks at joints and packings renewed as necessary.
8.6 During trip schedule - Yearly

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 crankcase 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.

14

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9. R E P A I R S

9.1 General
Only a skilled mechanic who knows about the compressor should be allowed to dismantle and
reassemble the compressor. Before dismantling the unit it is necessary to empty the air reservoir.
If necessary open the drain plug and drain all the lubricating oil.
9.2 Accessories
Take out the oil bath filters and their fittings loosen simultaneously both the ermeto nuts and
remove the suction pipes. Examine the cone seating and if worn out it should be changed. Remove
the safety valve from the dampening pipe and dismantle it. Examine the spring, valve seat and
rubber washer. Clean all parts and replace the parts as necessary. Reassemble and set the lifting
pressure on a test stand after testing for correct blowing off pressure tighten the lock nut.
9.3 Cylinder head, disc valves, Cylinder
Loosen the four hexagonal nuts on the cylinder head and remove the cylinder head. Proper care
should be taken 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). Damaged springs should be replaced with new ones. Also check packings and
if replace by a new one.
Loosen the four hexagonal nuts provided at the bottom of the cylinder and then gently lift and
remove the cylinder. Rotate the fan pulley and the cylinder will automatically come up.
9.4 Piston assembly
Remove the circlip by using the proper tool and gently knock out the gudgeon pin. Inspect for
scratches or slackness in the gudgeon pin boss. Replace pin if worn out. Remove the piston
rings using proper tool. Clean the piston rings grooves in the piston. Measure the ring gaps at
the butts and side clearances. Replace rings as a set when limiting clearances have been reached.

9.5 Cylinder, Piston and Piston Ring sizes and clearances

DESCRIPTION LP HP
+0.01 +0.01
-0.00 -0.00
Cylinder bore mm Dia 100 Dia 60
Piston mm Dia 99.835 -99.855 Dia 59.941-59.915

Ovel 0.075 ±0.015

+0.000 +0.000
Gudgeon pin size Dia 20 +0.000
-0.005 Dia 18 -0.005

Clearance in cylinder to piston, Normal mm 0.15 to 0.16 0.06 to 0.09

Max. mm 0.25 0.20

Permissible piston rings butt clearance, Normal mm 0.08 to 0.25 0.08 to 0.25
Max. mm 0.40 0.40

Permissible piston rings side play in groove Normal mm 0.04 to 0.08 0.06 to 0.09
Max. mm 0.12 0.12

Connecting rod small end needle roller bearing mm Dia 20 Dia 18

internal diameter

Clearance between piston crown and disc valve mm 1.4 to 1.6 1.4 to 1.6

15

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WEAR LIMIT IN CYLINDER
1. Up to +0.06 : Change new standard piston rings
2. From +0.06 : Change the cylinder

If the wear is beyond this limit, change cylinder, piston assembly completely.

9.6 Connecting rod and Crank shaft assembly

Worn out crank shafts can only be reconditioned by the manufacturer since it requires special
fixtures and precision equipment for dismantling and assembling. For dismantling the crank
shaft assembly from the crankcase first remove the fan and fly wheel the free end cover and then
remove the assembly along with the fly end cover. Remove fly end cover from the assembly by
slightly hammering the sides of the cover.

To remove the two main ball bearings on the crankshaft take a small steel wedge and gently
hammer it keeping it in between the crank wed and the bearing. Then use a suitable puller and
take out the bearings.

For fitting the main bearing on the connecting rod crankshaft assembly, heat the main ball
bearing gently on a hot plate which is heated by a flame or electricity uniformly. The bearing could
also be heated by immersing them in hot oil at 1000C. Then insert the bearings on to the shaft, so
that it will slide in and fit tightly on the shaft when cooled.

9.7 Assembling of crankshaft and connecting rod assembly in the crankhousing

Take the crankshaft assembly with side bearing and fix the fly end cover on the corresponding
bearing. Then take the crankshaft and connecting rod assembly and insert through fly end bore
of the crankcase and put the connecting rods on the correct sides. Tighten the fly end cover bolts.
Rotate the crankshaft by hand and ensure smooth rotation of the connecting rods. Then fix the free
end cover and gently tap it to position. Once again rotate the crankshaft and ensure that there is no
friction for the connecting rods to rotate. Then put the end cover bolts as usual.

When dismantling the crankshaft for repair purposes, you have to use pullers remove the end
covers. Two M 8 tapped holes are provided for this purpose. Tighten two bolts removed from the
cover into these holes. The cover will come out.

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9.8 Torgue chart

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

Sl. Location Thread size Tightening

No. torgue kg.m
1. Unit 1/2" BSW or M12 5.0
2. Motor 1/2" BSW or M12 5.0
3. Cylinder M12 x 1.75mm 5.0
4. Cylinder head M12 x 1.75mm 5.0
5. End cover , (Free end) M8 x 1.25mm 2.5
6. End cover, (Fly end) M8 x 1.25mm 3.0
7. Disc valve dia.100 M10 x 1.5mm 2.5
8. Disc valve dia. 60 M8 x 1.25mm 1.75
9. Drain plug 3/8" BSP 3.0

17

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1 0. STANDARD AND SPECIAL TOOLS

10.1 Standard 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. 12 mm stud tightening spanner

9. Circlip plier

10. Pipe wrench 9"

11. Screw driver 6"

10.2 Special Tools

S.No. Designation Part No.

1. Piston rings inserting tool, dia 60 00 04 1523 0
2. Piston rings inserting tool dia 100 00 04 1524 0
3. Piston rings expander dia 100 02 04 8719 0
4. Piston rings expander dia 60 02 04 8721 0

All these tools will be supplied on extra cost basis.

18

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11.TROUBLE SHOOTING

DEFECT LIKELY CAUSES REMEDIES

Compressor Dirty oil Change oil
over heats Oil level low Fill correct grade of oil up to maximum
level in the dipstick
Cylinder and inter cooler pipe Blow with compressed air or clean
fins dirty manually
Breather valve not working Open, clean and refit after checking
Wrong direction of rotation Interchange correct direction
Oil carryover in Chocked air filter Clean or renew the air filter element.
Compressed air Oil level high Drain to correct level
Oil viscosity too low Change to recommended grade
Breather not working Open, clean and refit after checking
Piston rings stuck in loosen the piston rings, if broken,
grooves or broken change the rings as a set. Check all
related parts for wear before fitting.
Piston to cylinder clearance Check and change as required
excessive
Unusual wear of Inadequate air filter Increase frequency of cleaning
cylinder, piston maintenance
and piston ring
Oil change frequency Increase frequency with more periodic
insufficient check of oil
Incorrect grade of oil Change to correct grade as given in
recommended lubricants chart.
Water or rust Faulty breather valve. Check and replace the breather valve
formation in if necessary.
crankcase
Oil leak through Breather valve is not working Open and refit the breather
breather valve
Piston rings stuck in Loosen the piston rings. If broken
Grooves or broken Change the rings as a set. Check all
related parts for wear before fitting.
Piston to cylinder clearance Check and change as required.
excessive.
Abnormal noise and Loose compressor Remove pulley and examine
Compressor Knocking pulley and key keyway and key for wear,
Change the key / pulley as required
Worn out piston, Overhaul compressor unit.
cylinder, crank shaft Replace the related components.
and connecting
rod bearings.
19

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 DEFECT LIKELY CAUSES REMEDIES
Pressure built up time Chocked air filter Renew new one
excessive. Loosen belts. Adjuster or replace, if elongated
Leak joints in Open and re-tighten with teflon
Pressure lines tape or jute and shellac.
Defective seating Open, clean and refit after careful
of inlet and delivery Check.
valve plates.
Worn out piston rings. Replace after checking the related
components.
Excessive belt wear Incorrect engine and Check and adjuster using a straight
compressor pulley edge or string across the diameter
alignment. of bolt the pulleys.
Incorrect belt tension. Check belt adjustments frequently.
Compressor package Uneven surface level. Check the surface with spirit level
vibration. and correct the surface level.
Mounting bolts Tighten bolts and nuts.
and nuts loose.

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12. RECOMMENDED SPARES

No. Description Qty. Drg./Part No.

12-1 Kit, spare parts, RAC Unit Model TRC 1000 B, 1 year 1 07 24 0336 9
1-1 Kit, Piston ring dia 100 2 02 24 0105 9
Each kit consists of -
a) Ring, plain compression, dia 100 2 -
b) Ring, stepped compression, dia 100 1 -
c) Ring, slotted oil control, dia 100 2 -
1-2 Kit, Piston ring dia 60 1 02 24 0103 9
Each kit consists of
a) Ring, plain compression, dia 60 1 -
b) Ring, stepped compression, dia 60 1 -
c) Ring, slotted oil control, dia 60 2 -
1-3 Kit combined disc valve, dia 100 2 02 24 0098 9
Each kit consists of
a) Spring, suction 1 00 04 1517 0
b) Plate, suction 1 00 04 1518 0
c) Spring, delivery 2 00 04 1520 0
d) Plate, delivery 1 00 04 1519 0
e) Gasket, big 2 00 05 1921 0
f) Gasket, small 1 00 05 1922 0
1-4 Kit, combined disc valve, dia 60 1 02 24 0103 9
Each kit consists of
a) Spring, suction 2 00 04 2435 0
b) Plate, suction 1 00 04 2434 0
c) Spring, delivery 2 00 04 2436 0
d) Plate, delivery 1 00 04 2433 0
e) Gasket, big 2 00 05 2406 0
f) Gasket, small 1 00 05 2407 0
1-5 Kit, safety valve assembly 3/8" BSP, 5 kg/cm2 1 07 24 0337 9
Each kit consists of
a) Seat, valve 1 00 05 1992 0
b) Spring 1 00 05 2153 0
1-6 Diaphragm - breather 2 00 05 1006 0
1-7 Seal, oil (B50 x 72 x 12) 2 00 04 2036 0

21

3835
 No. Description Qty. Drg./Part No.
1-8 Kit, Gasket and sealing parts TRC 1000 B 1 07 24 0338 9
Each kit consists of
a) Gasket, free end cover 1 00 04 3199 0
b) Gasket, fly end cover 1 00 04 3198 0
c) Gasket, crankcase to dia 100 & 60 cylinder - 0.75 mm 3 00 04 1004 C
d) Gasket, crankcase to dia 100 & 60 cylinder - 0.40 mm 3 00 04 1004 B
e) Gasket, crankcase to dia 100 & 60 cylinder - 0.25 mm 3 00 04 1004 A
f) Gasket, small - dia 100 disc valve 2 00 05 1922 0
g) Gasket, big - dia 100 disc valve 4 00 05 1921 0
h) Gasket, small - dia 60 disc valve 1 00 05 2407 0
i) Gasket, big - dia 60 disc valve 2 00 05 2406 0
j) Ring packing - dipstick 1 00 05 2196 0
k) Ring packing - drain plug 1 00 05 2186 0
l) Ring packing - Cylinder head to connecting housing 3 00 05 2183 0
m) Ring packing - Connecting housing to ermeto 3 00 05 2193 0
n) Packing, rubber - Oil bath air filter 1 00 04 7205 0

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

22

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 23

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13. P A R T S L I S T

24

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3835
78

75

25
FIG.2 RECIPROCATING AIR COMPRESSOR UNIT PACKAGE
MODEL TRC 1000B
13.1 RECIPROCATING AIR COMPRESSOR UNIT PACKAGE

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

I a.RAC Unit Package TRC 1000 B 1 S07 003
b.RAC Unit Package TRC 1000 B SAN 1 Z07002
1 Crankcase 1 07 03 0104 0
-2 Connecting rod & Crankshaft assy. W/O bearing 1 A07 0002
Connecting rod & Crankshaft assy. with bearing 1 07 03 0113 0
-3 Bearing, ball SKF 6310 2 00 09 03 361
-4 Cover, free end 1 00 03 1809 0
-5 Cover, fly end 1 00 03 1777 A
-6 Gasket, free end cover 1 00 04 3199 0
-7 Gasket, fly end cover 1 00 04 3198 0
-8 Bolt, hex, M8 x 20 6 00 09 06 115
-9 Washer, spring, M8 6 00 09 96 108
-10 Seal, oil B50 x 72 x 12 1 00 04 2036 0
-11 Key, woodruff 1 00 04 2044 0
a. Cooling fan and pulley assembly TRC 1000 B (incl. No. 12 to 21) 1 A02 0045
b.Cooling fan and pulley assembly TRC 1000 B SAN (incl. No.12 to 21) 1 A070064
-12 Flange, cooling fan 1 -
-13 Pulley, compressor 1 -
-14 Fan, cooling 1 -
-15 Bolt, hex, guide 4 00 04 1933 0
-17 Nut, hex M12 8 00 09 48 012
-18 Plate, locking 8 00 04 2401 0
-19 Bolt, hex. Guide 4 00 04 1932 0
-20 Bolt, hex. M8 x 12 9 00 09 06 111
-21 Washer, spring M8 9 00 09 96 108
-22 Washer, lock plate 1 00 04 3256 0
-23 Plate, lock 1 00 04 3257 0
-24 Nut, hex, M36 x 3 1 00 04 3258 A
-25 Dipstick with chain 07 04 0069 0 1 A07 0075
-26 Ring packing - Dipstick 1 00 05 2196 0
-29 Nut, Lock, 1/2" BSP 1 00 04 6602 0
-30 Pipe, breather 1/2" BSP 1 00 04 1361 B
-31 Reducer 1" x 1/2" BSP 1 00 04 3665 0
-32 Breather assembly 00 04 1138 0 1 A02 0030
*32A Chain assembly, breather 1 00 04 7317 0
-33 Plug asssembly, 3/8" BSP drain 00 04 3860 0 1 A02 0033
*34A Ring packing, drain plug 1 00 05 2186 0
-34 Cylinder dia 100 - disc valve 2 00 02 1010 A
-35 Gasket - Crankcase to dia 100 cylinder - 0.75 mm 2 00 04 1004 C
Gasket - Crankcase to dia 100 cylinder - 0.4 mm 2 00 04 1004 B
Gasket - Crankcase to dia 100 cylinder - 0.25 mm 2 00 04 1004 A
-36 Stud. M12 x 45 8 00 04 1456 0
-37 Nut, hex, M12 8 00 09 48 012
-38 Washer, spring M12 8 00 09 96 112
-39 Piston assembly, dia 100 2 00 04 1311 0
-40 Gasket, small - dia 100 disc valve 2 00 05 1922 0
-41 Gasket, big - dia 100 disc valve 4 00 05 1921 0
-42 Disc valve assembly, dia 100 cylinder 00 03 1204 0 2 A02 0042

26

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3835
78

75

27
FIG.2 RECIPROCATING AIR COMPRESSOR UNIT PACKAGE
MODEL TRC 1000B
 Fig. No. Description Qty. ELGI/Part No.
2-43 Head, dia 100 cylinder - DV 2 00 02 1239 A
-44 Stud M12 x 60 3 00 05 2013 0
-45 Stud M12 x 75 5 00 05 2014 0
-46 Nut, hex, M12 8 00 09 96 012
-47 Washer, spring, M12 8 00 09 96 112
-48 Bush, conn. rod small end -LP (Spare) 2 00 05 2311 A
-49 Housing, connecting 1" x 3/4 2 00 042764 0
*49A Ring, packing - Cyl.head to connecting housing 3 00 05 2183 0
-50 Gasket, crankcase to dia 60 cylinder 0.75 mm 1 00 04 1004 C
Gasket, crankcase to dia 60 cylinder 0.40 mm 1 00 04 1004 B
Gasket, crankcase to dia 60 cylinder 0.25 mm 1 00 04 1004 A
-51 Cylinder dia 60 - disc valve 1 00 02 1011 A
-52 Stud M12 x 54 3 00 05 1455 0
-52A Stud M12 x 70 1 00 05 1883 0
-53 Washer, spring, M12 4 00 09 96 112
-54 Nut, hex, M12 4 00 09 48 012
-55 Piston assembly, dia 60 1 00 04 1312 0
-56 Gasket, small - dia 60 disc valve 1 00 05 2407 0
-57 Gasket, big - dia 60 disc valve 2 00 05 2406 0
-58 Disc valve assembly, dia 60 cylinder, 00 03 1381 0 1 A07 0017
-59 Head, dia 60 cylinder - DV 1 00 02 1302 0
-60 Stud, M12 x 54 4 00 05 1455 0
-61 Washer, spring M12 4 00 09 96 112
-62 Nut, hex, M12 4 00 09 48 012
-63 Bush, connecting rod small end - HP (Spare) 1 00 05 2120 A
-64 Housing, connecting 7/8" x 3/4" BSP 1 00 04 2765 0
-65 Pipe, bend RH - Air filter 1 00 04 2115 0
-66 Pipe, bend LH - Air filter 1 00 04 2115 A
-67 Filter assembly, oil bath inlet, 00 04 2085 A 2 A07 0009
-67A Bush rubber, oil bath inlet air filter 2 00 04 3218 0
-68 Flat, support - Bend pipe 2 00 04 3569 0
-69 Bolt, hex, M8 x 20 2 00 09 06 115
-70 Washer, spring, M8 2 00 09 96 108
-70A Washer, plain, M8 2 00 09 96 058
-71 Nut, hex, M8 2 00 09 48 008
-72 Ermeto 3/4" x 1" BSP 6 00 04 1017 0
-73 Cone, ermeto, 1" BSP 6 00 04 1924 0
-74 Nut, ermeto, 1"BSP 6 00 04 1928 0
-75 Pipe assembly, connecting - No.3 1 00 03 3402 0
-76 Ring, packing - Conn. Housing to ermeto 3 00 05 2193 0
-77 Dampening pipe (intercooler) 1 00 04 2819 0
-78 Pipe assembly, connection - No.2 2 00 03 3401 0
-79 Valve, safety 3/8" BSP 00 04 1318 Z 1 A02 0002
-80 Plate, name 1 -
-81 Rivet 4 -
-82 Decal, direction indicator name plate 1 -
-83 Rivet 2 -
-84 Nipple, 3/4" x 3/4" BSP 1 00 05 1123 0
-85 Elbow 3/4" BSP M 1 00 09 72 004
-86 Ermeto 1" x 3/4" BSP 1 00 04 1017 0
* Not shown in the drawing

28

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 FIG. 3 PISTON ASSEMBLY DIA 100 FIG. 4 PISTON ASSEMBLY DIA 60

FIG. 5 SAFETY VALVE ASSEMBLY 3/8" BSP

29

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13-3 PISTON ASSEMBLY DIA. 100

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

3 Piston assembly Dia. 100 1 00 04 1311 0
3-1 Plain compression ring 2 -
-2 Stepped compression ring 1 -
-3 Slotted oil control ring 2 -
Piston with Gudgeon Pin (Incl.No.4,5) 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 PISTON RINGS DIA 100 (Consists of No. 1,2,3) 1 02 24 0105 9

13-4 PISTON ASSEMBLY DIA. 60

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

4 Piston assembly Dia. 60 1 00 04 1312 0
4-1 Plain compression ring 1 -
-2 Stepped compression ring 1 -
-3 Slotted oil control ring 2 -
Piston with Gudgeon Pin (Incl.No.4 to 5) 1 00 04 7773 0
-4 Piston dia. 60 1 -
-5 Gudgeon pin dia. 18 1 00 05 1418 0
-6 Circlip B18 2 00 09 1721 0
KIT PISTON RINGS DIA 60 (Consists of No. 1,2,3) 1 02 24 0103 9

13-5 SAFETY VALVE ASSEMBLY 3/8" BSP

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

5 Safety valve assy. 3/8" BSP 00 04 1318 0 1 A02 0002
5-1 Housing 1 -
-2 Valve Seat 1 -
-3 Valve cone 1 -
-4 Spring 1 -
-5 Pressure adjuster 1 -
-6 Lock nut 1 -
-7 Locking pin 1 -
-8 Actuating rod 1 -
-9 Knob 1 -
-10 Split pin. 1 -
Safety item, supply as assembly only

30

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 1 2 3

6
7

8
9

FIG. 6 FILTER ASSEMBLY, OIL BATH AIR INLET

FIG. 7 VALVE ASSEMBLY BREATHER FIG. 8 VALVE ASSEMBLY DRAIN

31

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13-6 FILTER ASSEMBLY, OILBATH, AIR INLET

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

6 Filter Assembly, Oil bath, Air inlet 00 04 2085 A 1 A07 0009
6-1 Wing nut M5 1 00 04 53 23 0
-2 Plain washer 1 00 09 9600 6
-3 Filter element 1 -
-4 Rubber packing 1 00 04 7205 0
-5 Bottom cover 1 -
-6 Clamp 1 00 04 2113 0
-7 Hex. nut M6 1 00 09 4800 7
-8 Hex. blot M6 x 30 1 00 09 0608 8
9 Bush Rubber 1 00 04 3218 0

13-7 VALVE ASSEMBLY BREATHER

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

7 Valve Assembly Breather 00 04 1138 0 1 A02 0030
7-1 Breather bottom 1 -
-2 Diaphragm 1 00 05 1006 0
-3 Breather top 1 -
-4 CSK Screw M6 x 10 2 00 05 2069 0

13-8 VALVE ASSEMBLY DRAIN 1/4" BSP

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

8 Drain Valve Assembly 1/4" BSP 00 05 1541 0 1 A02 0045
8-1 Housing 1 -
-2 Cone seat 1 -
-3 Valve seat 1 00 05 1993 0

32

3835
 FIG. 9 DISC VALVE ASSEMBLY, DIA. 100

FIG. 10 DISC VALVE ASSEMBLY, DIA. 60

33

3835
13-9 DISC VALVE ASSEMBLY, DIA. 100

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

9 Disc valve assembly (00 03 1204 0) 1 A02 0042

9-1 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 96 110

-11 Hex. nut M10 1 00 09 48 010

KIT COMBINED DISC VALVE, DIA 100 1 02 24 0098 9

(CONSISTS OF NO : 5,6,7,8)

13-10 DISC VALVE ASSEMBLY, DIA. 60

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

10 Disc valve assembly (00 03 1381 0) 1 A07 0017

10-1 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 96 108

-9 Hex. nut M8 1 00 09 48 008

KIT COMBINED DISC VALVE, DIA 100 1 07 24 00 989

(CONSISTS OF NO : 3, 4, 5, 6)

34

3835
N O T E S

35

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 35

3835
 INSPECTION AND SERVICE RECORD

Scheduled Results of Inspection and outline of service

Date of Date of
Date of Next Oil Piston Ring Air Delivery Pipe, Inspected or
Inspection Completion
of Service
Inspection and Exchange & Cylinder Valve Pipe Seat Others Service by
Service Air Tank