I.

C O M PA N Y PROFILE

Elgi Equipments Ltd is the technologically innovative company with four decades of
expertise in the manufacture of compressors, based in Coimbatore, India. ELGI is one of the
largest manufacturers of compressors and also a leader in Automotive Service Equipment and
Diesel Engines.

An ISO 9001 company practicing Six Sigma and TPM, ELGI employs best in class
practices and provides total in-house capabilities to design and manufacture products
to meet international standards.

ELGI is driven by the principle of "Extra Engineering". It means building extra value into
everything we do, right from concept to design, development to manufacturing, marketing,
delivery, service and knowledge sharing.

ELGI manufactures a comprehensive range of products for compressed air

applications such as Reciprocating Air Compressors. Rotary Screw Air Compressors both
Oil-flooded and Oil-free and Centrifugal Air Compressors. ELGI also manufactures the Airmate
range of Air Treatment downstream auxiliary accessories - Refrigeration Air Dryers,
combination Air Filters, Air Receivers, Jack Hammers and more.

ELGI has a committed and technically strong team of 1100 with 325 engineers. ELGI
operates from two state of art manufacturing plants in Coimbatore, India with 30 acres of land
and around 350,000 sq. feet of built up factory area. Elgi operating out of an advanced and
sophisticated manufacturing facility with R&D and CAD facilities, a totally integrated machine
shop, CNC helical rotor cutting machines, tool management centers, and Metrology
Laboratory.

ELGI has collaborations and technical tie-ups with leading foreign companies,
institutions and consultants that ensure ELGI remains at the cutting edge of manufacturing
technology. Axis Airends are designed and developed by ELGI under joint technology
agreement with the Positive Displacement Compressor Technology Research Centre at City
University, London. Also entered joint venture with M/s.Hitachi Limited, Japan for
manufacturing Oil Free Screw Air Compresor & with M/s.Samsung Tech win Company
Limited, Korea for producing Centrifugal Air Compressors.

ELGI has a vast network of sales and service outlets manned by well-trained, highly
qualified and motivated engineers worldwide. Elgi is a leading exporter of top blocks of
reciprocating air compressors and Air Ends of Screw Air Compressor for OEM's and complete
compressor packages all over the world.

ELGI truly has a global presence, with over 30 percent of its production reaching
end-users and OEM's in the USA, Europe, Australia, South East Asia and Middle East.

Based on the firm foundations of reliability, technology, capability and value, Elgi faces
the future with confidence. We are today in a strong position to strike new partnerships for
growth, and drive through mergers and acquisitions, to keep abreast with the latest technology
from around the world. As always, innovation will continue to be our key differentiator. To bring
better products and services that put a smile on the face of our customer

3
II. P R E A M B L E

01. Thank You Thank you for purchasing this quality product. This modern pneumatic
machine has been designed to provide you with many hours of
useful service.
This Operation and Maintenance Manual provides you with easy to
understand operating instructions. Read the entire manual and follow
all the instructions to keep your new pneumatic machine in top
operating condition.
This manual comprises of a parts list in addition to a
recommended spares list, providing you information that you need
to order parts.

02. Product References, All information, illustrations and specifications in this manual are
Illustrations and based on the latest product information available at the time of
printing.
Specifications

03. Service Information Service on this pneumatic machine within and after the warranty
period, can be performed by any ELGI branches and authorised
distributors / dealers.
To obtain the listing of ELGI branches and authorised
distributors / dealers in your area.

DOMESTIC : DIAL : 0091 - 0422 - 2589555

FAX : 0091 - 0422 - 2573697

INTERNATIONAL : DIAL : 0091 - 422 - 2589555

FAX : 0091 - 422 - 2576849

TOLL FREE NO. : 1800 - 425 - 3544

4
III. U S E R S ' IMPORTANT
I N F O R M A T I O N
1. Attend to any signs of minor irregularities immediately. If
neglected, they could become worse.

NOTE
Make sure this manual is read and carefully
understood before starting/ operating this
machine.

2. In case of any requirement of spares or service, please

contact our nearest dealer / distributor.

3. Only manufacturer supplied parts to be used in the repair of

this compressor in order to obtain satisfactory operation.
Commercially available parts are unacceptable.

4. Whenever a part is replaced in this compressor, the

compressor shall pass a series of test specified in the Wear
In Test and Compressor Capacity tests column. Ensure that
the air compressor functions properly in the total braking
equipment arrangement in a stationary vehicle.

5. Retain this manual carefully throughout the life of the

equipment, in order to procure correct spares.

6. While ordering spare parts the following particulars must be

clearly mentioned to ensure supply of the right spares.

1. Model : RR 15 070

2. Fabrication no.

3. Year of manufacture

4. Part Description

5. Part number

6. Required quantity

7. Due to improvements being made continuously, the

illustrations and descriptions on this manual are subjected
to change.

5
IV. T A B L E O F
C O N T E N T S

SI. Page
Description Number
No.

I. Company Profile ......................................................................................................................... 3

II. Preamble ...................................................................................................................................... 4

III. User’s Important information .................................................................................................... 5

IV. Table of contents ....................................................................................................................... 6

V. Preface ......................................................................................................................................... 8

VI. Do’s and Dont’s .......................................................................................................................... 9

1. General Description ................................................................................................................. 10

2. Safety procedure and warnings ............................................................................................. 12

3. Technical Data .......................................................................................................................... 15

4. Abbreviation for RR15 070 ..................................................................................................... 17

5. Description of parts ................................................................................................................. 17

5.1 Cylinders .......................................................................................................................... 17

5.2 Cylinder Heads and Valves .......................................................................................... 18

5.3 Crankshaft and connecting rod assembly .................................................................. 18

5.4 Pistons & Rings .............................................................................................................. 19

5.5 End covers ....................................................................................................................... 20

5.6 Crankcase ........................................................................................................................ 20

5.7 Oil seal ............................................................................................................................. 21

5.8 Inter cum after cooler .................................................................................................... 21

5.9 Breather valve ................................................................................................................. 22

5.10 Wire rope Isolator ........................................................................................................... 22

5.11 Suction filter .................................................................................................................... 22

6. Cleaning solvants & Lubricants ............................................................................................. 22

7. Replacement Parts ................................................................................................................... 23

8. Maintenance Schedule ............................................................................................................ 23

9. Handling the compressors ...................................................................................................... 25

9.1 Remove the compressor from coach .......................................................................... 25

9.2 Lifting the compressor & Lifting provision ................................................................. 25

6
SI. Page
Description Number
No.

10. Repair procedure in Shop ...................................................................................................... 26

10.1 General ............................................................................................................................. 26

10.2 Dismantling the the compressor block ....................................................................... 26

10.3 Removal of fan assembly ............................................................................................. 27

10.4 Motor Disassembly ......................................................................................................... 28

10.5 Crankshaft Disassembly ................................................................................................ 29

11. Cleaning Repairing ................................................................................................................... 30

12. Assembly ................................................................................................................................... 30

12.1 Compressor block assembly ......................................................................................... 30

12.2 Cooler & pipe line asembly .......................................................................................... 31

12.3 Motor assembly ............................................................................................................... 31

13. Restarting the compressor after long period ....................................................................... 33

14. Torque values ........................................................................................................................... 33

15. Tool list ...................................................................................................................................... 34

16. Recommended spares List for AOH ..................................................................................... 35

17. Parts List ................................................................................................................................... 36

17.1 Compressor Package ..................................................................................................... 38

17.2 Compressor Unit ............................................................................................................. 40

17.3 Compressor block ........................................................................................................... 42

17.4 Motor assembly ............................................................................................................... 46

17.5 Filter assembly ................................................................................................................ 48

17.6 Piston assembly dia 90 ................................................................................................. 50

17.7 Piston assembly dia 60 ................................................................................................. 52

17.8 Breather valve assembly ............................................................................................... 54

17.9 Drain valve assembly .................................................................................................... 54

18. Motor operating instructions & Maintenance manual ......................................................... 57

7
V . P R E F A C E

This Reciprocating Air Compressor has been designed and

manufactured with utmost skill and care, with maximum
reliability and high quality standards as per the requirements
and specifications conforming to International Standards.

ELGI Compressor genuine parts, manufactured to design

tolerances, are developed for optimum dependability –
specifically for ELGI compressor systems. Design and material
innovations are the result of years of experience with hundreds
of different compressor applications. Reliability in materials and
quality assurance is incorporated in our genuine replacement
parts.

This manual has been prepared and compiled with utmost care
to help the user to know the various systems involved in the
compressor thoroughly and to operate it to his best advantage.
It incorporates detailed description of all systems and working
conditions with relevant diagrams and drawings.

Before attempting to use the compressor, the user shall go

through this book carefully to get acquainted with this
equipment to ensure best results. Under normal working
conditions and with regular prescribed periodic preventive
maintenance, excellent, trouble free service can be guaranteed
for several years. In case of necessity, our service can always
be counted upon.

Our authorized distributors/ dealers offer the entire backup you’ll

need. A worldwide network of authorized distributors provides
the finest product support in the air compressor industry.

Specify exactly the number of parts required. Do Not Order By

Set or Groups.

To determine the Right Hand and Left Hand side of a

compressor, stand at the non drive end side and look towards
the compressor. Right Hand and Left Hand are indicated in
following part name, i.e. RH & LH, when appropriate.

8
VI. DO'S AND DON'TS

Dos 3 Read the manual in detail and follow the instructions.

3 Clean the air compressor package regularly.

3 Use only genuine spares.

3 Use only clean, recommended lubricants.

3 Use proper tools.

3 Attend immediately to anything unusual with the air

compressor.

3 Complete Repairs/ Service with qualified technicians

only

Don'ts
7 Neglect the routine attention.

7 Allow any water / airleakage in the system.

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

modules.

7 Meddle with any adjustments or settings in the safety

valve.

7 Do any repair work while the compressor is running.

9
1. G E N E R A L
DESCRIPTION
1.1 General Description The compressor model RR15070 is a two stage, reciprocating ‘W’
type, splash lubricated and with Air-cooled cooling system. It is
designed for providing compressed air to braking system of EMU
Coach. This compressor is driven by an AC Electric Motor. The
compressor is designed for operation at a discharge pressure of 7
Kg/cm2 and can be operated upto maximum pressure of 10 kg/cm2

Figure 1- Schematic view of the Compressor

The above figure gives a clear view of the compressor operation.

When the piston of the Low pressure cylinder moves towards the
Bottom Dead Center the combined action of the delivery valve return
spring and the pressure differential developed between discharge
manifold and the Low Pressure Cylinder closes the delivery valves.
At the same time, inlet valves open due to the pressure differential
developed between the inside and outside of low pressure cylinder.
Air at atmospheric pressure is drawn in through the suction filter
and intake valves into the low pressure cylinders during the downward
strokes of the pistons.

10
 During the upward motion of the piston, the combined action of the
inlet valve springs and the pressure differential developed between
the inside and outside of the Low Pressure cylinder closes the inlet
valves. The air, which is trapped in the cylinder, gets compressed.
The compressed air forcibly opens the delivery valves due to the
formation of pressure differential, which has been developed between
the discharge manifold and the cylinder. Air leaves the intercooler,
entering the high pressure cylinder through its intake valve. As the
high pressure piston moves upward, it compresses the air to a higher
pressure, forcing it out through the discharge valve and connecting
pipe to the After cooler. Air leaving
the After cooler is connected to the application line in the EMU Coach.
A safety valve is mounted on the intercooler, which relieves the
pressure beyond 5 Kg/cm2. Both first and second stages receive
power from the crankshaft.

Cooling System Both the low-pressure cylinders are connected to the Aluminium
Intercooler through a stainless steel pipe. Fan that is located behind
the cooler sucks the atmospheric air through cooler fins. The cold
air is delivered to the High pressure Cylinder. The outlet of High
pressure cylinder is connected to After cooler. The hot air is cooled
as same manner of Low pressure. The outlet of After cooler is taken
for application.

11
2. S A F E T Y
PROCEDURES AND
W A R N I N G S

Safety Precautions All situation or circumstance cannot always be predicted and

covered by established rules. Therefore, use your past
experience, watch out for safety hazards and be cautious.

Some general safety Precautions are given below:

ELGI compressors are the result of advanced engineering,

skilled manufacturing and Quality Systems. To be assured of
receiving maximum service from this machine the owner must
exercise care in its operation and maintenance. This book is
written to give the operator and maintenance department
essential information for day-to-day operation, maintenance
and adjustment. Careful adherence to these instructions will
result in safe way of handling, economical operation and
minimum downtime.

DANGER
Danger is used to indicate the presence of a
hazard, which will cause severe human injury or
substantial property damage if the warning is
ignored.

WARNING
Warning is used to indicate the presence of a
hazard, which can cause severe human injury or
substantial property damage if the warning is
ignored.

CAUTION
Caution is used to indicate the presence of a
hazard, which will or can cause minor human
injury or property damage if the warning is
ignored.

NOTICE
Notice is used to notify people of installation,
operation or maintenance information, which is
important but not hazard-related.

12
 Failure to observe these notices could result in human injury.
DANGER • Do not operate unit if safety devices are not operating
properly.

• Do not use the air from this unit for breathing – not
suitable for human consumption.

• Disconnect the Electrical wires from its source, tag and

lockout before working on the Compressor unit.

• Do not loosen or remove the oil filler plug, drain plugs, cover,
or break any connections, etc., in the compressor air or oil
system until the unit is shutdown and the air pressure has
been relieved.

• Do not modify unit without written permission from original

equipment manufacturer.

Failure to observe these notices could result in damage to

WARNING equipment.

• Stop the unit if any repair or adjustments on or around the

compressor are required.

• Do not exceed the rated maximum Pressure values shown

on the name plate.

• Do not pass any electric current on the compressor or base.

• This compressor is designed for use in the compression of

normal atmospheric air only. No other gases, vapors or fumes
should be exposed to the compressor intake, nor processed
through the compressor.

• Inspect the Crankcase for Fatigue cracks and inspect all pipe
and tube connections and fasteners for looseness.

• Be sure to check the rotating direction, otherwise the unit

may overheat and be damaged or fail.

l Do not operate the compressor in excess of its rated

capacity, speed, pressure and temperature, nor otherwise
than in accordance with the instruction contained in this
manual.

l Do not start the compressor without filling the oil to

recommended level.

13
 Failure to observe these notices could result in human
CAUTION injury.

• The use of an air jet, which must be less than 2 kg/cm2, to

blow parts clean or to blow them dry after being
cleaned with a solvent will cause particles of dirt and or
droplets of the cleaning solvent to be airborne. These
conditions may cause skin and/or eye irritation.

• When using an air jet do not direct toward another person.

Improper use of air jet could result in bodily injury.

• The use of solvents as cleaning agents and the use of

lubricants can involve health and/or safety hazards. The
manufacturers of the solvents and lubricants should be
contacted for safety data (such as OSHA Form OSHA-20 or
its equivalent). The recommended precautions and procedures
of the manufacturers should be followed.

• Assembly may be under a spring load, exercise caution

during disassembly so that no parts “Fly Out” and cause bodily
injury.

• Before removing any pressurized parts, effectively isolate

the unit from all sources of pressure and relieve the entire
system out of pressure.

• Always wear ear protection to protect hearing.

• Personal eye protection must be worn and care taken to avoid

possible injury when performing any work on this device and/
or component part.

• Use insulated gloves, when performing maintenance work.

14
3. TECHNICAL D ATA

a) Compressor

1 Model RR 15 070

2 Type Reciprocating ‘W’ type, Air cooled,

Forced Lubricated with Inter and
after cooling System

3 Direction of Rotation Anti-Clockwise when viewed from Motor

non drive end

4 Working Pressure kg/cm 2 7 (10 Max)

5 Design Pressure kg/cm 2 15

6 Displacement m 3 /h 94.8
cfm 55.79
lpm 1580

7 Free air delivery m 3 /h 72

cfm 42.37
lpm 1200

8 Number of stage 2

9 Number of LP cylinder 2

10 LP Cylinder size mm 90

11 HP Cylinder size mm 60

12 Stroke length mm 85

13 Compressor speed rpm 1460

14 Shaft power HP 13.5

15 Type of valve Concentric combined disc valve for

LP & HP

16 Type of drive Directly coupled with motor through

taper shaft

17 Crankcase oil capacity ml Min. 2300

Max. 3650

18 Recommended oil SERVO PRESS 150

19 Safety valve setting on kg/cm 2 5

intercooler

15
20 Safety valve setting on kg/cm 2 8.5
Aftercooler (Not in Elgi
scope of supply)

21 Air outlet temperature from A/C Deg C Less than 15 + ambient

22 Filter Dry type, low noise

23 Overall dimensions L x W x H mm 960 x 705 x 680

24 Net weight of compressor with kg 300

motor and mounting bracket

b) Motor

1 Make ELGI ELECTRIC

2 Type Special Hollow Rotor

3 Power HP 15

4 Voltage V 415 ± 10% AC

5 Rated current at 415 V Amps 20

6 No of phase Three Phase

7 Frequency Hz 50 ± 5%

8 Protection IP - 57 S

9 Class of insulation H

10 Method of cooling TEFC

11 Speed rpm 1460

12 Rating Continuous

13 Mounting Foot cum flange mounting

16
4. ABBREVIATION FOR RR 15 07 0

RR 15 07 0

Railway Reciprocating

Power (HP)

Outlet Pressure (Kg/cm ) 2

Motor Driven

5. DESCRIPTION
O F P A R T S

5.1. Cylinders This Compressor has two 90mm diameters Low Pressure Cylinders
and one 60mm diameter High Pressure Cylinder. Cylinders are made
of high grade Grey iron Castings with fins for better cooling

Figure 2 : Low Pressure Cylinder Figure 3 : High Pressure Cylinder

17
5.2. Cylinder Heads and valves This Compressor is equipped with three cylinder heads (2 LP & 1
HP) that has integral fins for better cooling. All inlet & outlet ports
are provided with elliptical flange for leak proof connections. The
valves are combined concentric disc type, loaded with springs,
operated due to the differential pressure between the upstream and
downstream pressure.

Figure 4 Figure 5
Low pressure cylinder head High pressure cylinder head

Figure 6
Combined concentric disc valve

5.3. Crankshaft and connecting The crankshaft is a three-piece construction and made out of special
rod assy alloy forged steel. It is precision machined, ground and dynamically
balanced. High-pressure stage connecting rods is made of forged
and assembled together the crankshaft. Connecting rod big end is
provided with steel bearing rollers and small end is provided with
needle roller bearing. Low-pressure connecting rods are connected
with Main connecting rod in the Eye end. Crankshaft & connecting
rod assembly makes an integral part.

18
 The crankshaft is provided with single row heavy-duty ball bearing
at both ends. Crank shaft fly end is having taper so that it can be
coupled Rotational motion of the crankshaft is converted to
reciprocating motion by slider crank mechanism. Rotation of the
crankshaft is in a counter clockwise direction as viewed from drive
end.

Figure 7: Crankshaft

5.4. Pistons and Rings The Pistons are made of low expansion aluminum alloy and
elliptically ground on the outside diameter. Both low pressure and
high-pressure pistons have two overlap Perma-Seal compression
Rings and two oil control Rings. Compression rings are made of
closegrained cast iron. Oil control rings are made of stainless steel
with chrome plated and having three piece constructions.

Figure 8: Low Pressure Piston Figure 9: High Pressure Piston

19
 5.5. End covers End Cover is made of Cast iron, which has more stiffness and
deflection is minimized. This houses one main bearing and two
numbers threaded holes are provided for ease of end cove removal
from crankcase. Fly End cover is also used as motor mounting
bracket

Threaded
Figure 11: End cover free end
Figure 10: End cover fly end holes for
removal

5.6. Crankcase The crankcase was employed as a sump for the lube oil, which can
hold 3.65 liters of lube oil. The RH side wall in the crankcase is
provided with an oil filing cum overflow port which prevents over
filling of oil. This oil filling port is closed with a threaded cap & dipstick.
Dipstick is used to monitor the oil level in the crankcase. The oil
level should be above the min level marking.The crankcase has one
elliptical mounting flange with breathing hole. This is used to connect
Breather Valve. One No. M10 through hole is provided in the free
end side to insert M10x50 bolt for locking the crankshaft during Motor
assembly & removal.

Breather
Port

Hole for
Shaft locking
Drain
Port
Oil filling
port
Figure 12 : Crankcase

20
 5.7. Oil Seal An oil seal is provided on the Fly end & Free end sides. This seal
is a lip type and is normally composed of a nitrile rubber material.
A coil spring is molded into the lip area of the seal to maintain a
constant seal lip pressure against the crankshaft and ensure
proper sealing, which prevents oil leaks from crankcase to Motor
and outside.

5.8. Inter cum aftercooler The cooler is made of Aluminium tubes for lower weight and have
the patrician internally for Intercooler and Aftercooler. The
intercooler reduces the temperature of the compressed air leaving
the first stage prior to entering the second stage in order to improve
the overall thermodynamic efficiency of the system. The
aftercooler reduces the temperature of the compressor air leaving
the final stage so that downstream brake equipment gets the cool
air. Drain valve is provided at the bottom of the intercooler to
drain the condensate collected in the intercooler. A safety valve
is provided on the intercooler, which opens at 5 Kg/cm2 .

WARNING
It is important that the safety valve be maintained
in good working order and that the pressure
setting is such that the safety valve will provide
pressure relief ifthe intercooler pressure exceeds
5 Kg/cm2. Failure to comply with this warning may
result in serious injury to workmen and/or
bystanders.

Safety Valve
Position

Drain Valve
Position

Figure 13: Inter cum After cooler

21
 5.9. Breather Valve The breather assembly is mounted on the crankcase. It operates as
a check valve to provide a partial crank case vacuum during normal
operation of the compressor and to discharge air displaced in the
crankcase during the compression process. The diaphragm assembly
in the breather assembly acts as a one-way valve, which allows the
air to flow through it from the crankcase to atmosphere. This process
maintains adequate vacuum inside the crankcase.

5.10. Wire rope isolator The Wire rope isolator acts as vibration reducer and shock observer.
It prevents the transmission of shock loads to Coach during
compressor running. Wire rope is made of high quality stainless steel
and Retainer bars are made out of Aluminium alloy.

5.11. Suction filter The Dry type suction filter is used and mounted directly along with
compressor. The filter is designed to reduce the compressor noise to
low level.

6. C L E A N I N G
SOLVENTS AND
L U B R I C A N T S

6.1. Cleaning Solvents The solvent used to clean specified reusable metal parts MUST BE
an aliphatic organic solution, such as mineral spirits that will dissolve
oil or grease, and that will permit the parts to be cleaned without
abrasion. Alkaline cleaners may be used to clean aluminum type
Pistons.

IMPORTANT: No caustic cleaners are to be used on aluminum

pistons.

6.2. Lubricants Use only SERVO PRESS 150 Oil

22
7. REPLACEMENT
P A R T S
Orders shall be placed on the Part Number, Description and Quantity
specified in the parts catalog. Figure and Reference Numbers are for
reference ONLY, not to be used while ordering the parts.

IMPORTANT: To obtain satisfactory operation of the compressor

ONLY parts supplied by the ELGI shall be used.

8. MAINTENANCE
S C H E D U L E

It is recommended that the procedures listed in this maintenance

schedule be performed at least once during the specified time period
or more frequently if service conditions so indicate. Failure to perform
the procedures at the specified time period may result in damage to
equipment, which could possibly cause a malfunction that may result
in property damage and/or bodily injury. More frequent maintenance
intervals may be found necessary, depending on the severity of the
service to which the compressor is subjected. IT IS THE USER’S
responsibility to determine if more frequent schedules for maintenance
are required.

The below mentioned schedule is applicable for ELGI genuine spare

parts & proper maintenance

IMPORTANT:
The overhaul period represents the TIME PERIOD between
overhauls that is recommended. The actual time of compressor
operation or service before an overhaul is performed is heavily
influenced by the type of service in which the compressor is
used, the mileage of the Coach between overhauls, the ambient
temperature in which the compressor operates, the duty cycle
of the compressor, oil change periods, the environmental
conditions, and inlet air filtration. The actual time periods
between overhauls MUST BE established by the USER and
should be based on USER conditions and experience.

The compressor is to be removed from the Coach for overhaul

utilizing genuine ELGI replacement parts.

23
The below mentioned schedule is applicable for ELGI genuine spare parts & proper maintenence

24
9. HANDLING THE
COMPRESSOR
9.1. Removing the compressor WARNING: A lifting and support mechanism capable of safety
from the coach handling 500 Kgs is to be used during compressor removal.

All power to the compressor is to be cut-off and remove the Electrical

connection. Wheel chocks are to be applied to the wheels to prevent
vehicle movement.

WARNING placards are to be placed on and about the vehicle

indicating that work is to be performed. It is advised to use Fork lift or
Hydraulic lift to remove the compressor from coach. Place a proper
platform in-between the Forks of the lift and hold the compressor.
The compressor side and Motor side support should rest on the
platform evenly.

Motor side
support
Compressor side
support
Figure 14.

Loosen the Bolts which is used for mounting the Wire rope Isolator
with Coach frame. Down the lift and bring the compressor to outside
of Coach.

9.2. Lifting the compressor &

lifting provision
Lifting Hook

Use the Lifting Hook at three places as indicated to avoid damage

to parts. Special lifting Hook (Drg No. 070406730) as indicated shall
be purchased from ELGI

25
10. REPAIR PROCEDURE
- I N S H O P

10.1. General Before the compressor is disassembled, the exterior surfaces of

the unit MUST BE thoroughly cleaned. Parts should be marked to
ensure that each would be reassembled in the proper location.
Care should be taken when handling parts so as not to damage
parts. When cleaning the parts, do not put main bearings,
crankshaft, valves, pistons, piston rings or wrist pins in the same
basket with other compressor parts.

Cylinder heads, cylinders, crankcases and end covers should be

placed in a cleaning solution and lefts there long enough to ensure
proper cleaning. After removal from the cleaning solution, these
parts should be wire brushed and magnetic- particle inspected
for defects.

The pistons, crankshaft and connecting rods should be thoroughly

cleaned (DO NOT WIRE BRUSH) and magnetic-particle inspected
for defects. After magnetic-particle inspection all parts should be
re-washed and demagnetized before re-assembly. Use a
low-pressure jet of clean, dry air to blow the surface clean. DO
NOT USE CAUSTIC cleaners on the aluminum pistons.

10.2. Dismantling the • Place the compressor on the assembly table and bolt the
compressor block compressor side foot rest for ease of work. (Center distance of
two mounting holes is 460 mm). Use M12 x 50 bolt

Fig.15
26
 Refer the Compressor Unit Part No. X070102
(Refer Fig. 26 for parts list)

l Drain the water from inter cooler by opening drain Valve

(Item 25)

l Remove drain plug at bottom of crankcase and drain the oil.

l Remove the Filter Assembly by loosening M16 Bolts

l Remove the Suction Manifold (Item 4)

l Remove the pipe lines (Item 3, 19 and 20)

l Remove the cooler along with Fan guard (Item 18 & 17) by
removing M10 bolt between cooler and cooler bracket.

Refer the Compressor Block Part No. X070101

(Refer Fig. 27 for parts list)

l Remove the Cylinder Heads (Item 26 & 30) by loosening

M12 Nuts.

l Remove the Valves (Item 25 & 29) carefully.

l Remove the Cylinders (Item 17 & 18) by loosening M12 Nuts

l Remove the Breather (Item 39)

l Remove the Circlip (Item 15) and Gudgeon Pin and then take
out the Pistons (Item 13 & 14)

10.3. Removal of fan assembly l Lock the rotor as below and remove the Left Hand Nut M16
(Refer Fig. 26 for parts list)
(Item 15).

Fig.16

This one thread at Free end is provided to through opening. Replace

the existing Bolt M10 x 20 by Bolt M10 x 50 to lock the shaft rotation.
Rotate the Fan slightly if the bolt is not entering fully due to
interference with Web.

27
 Pull the Fan outside. Slight hammering using Nylon hammer may be
required.

DANGER
DANGER : Remove the Locking Bolt M10x50 &
re-assemble with M10x20 before run the
compressor. Failure to do this will lead damage
to compressor.

10.4. Removal of motor Assembly l Lock the rotor as per procedure mentioned above
(Refer Fig. 25 for parts list)
l Remove the Motor side Mounting Brackets (Item 13)

l Remove the Motor Fan cover

l Remove the Motor Fan by loosening Nut M16 (Item 9)

l Remove the Motor Bearing outer cap as shown

Motor bearing
cover

Fig-17, Motor bearing

cover removal

Motor Rear Cover

Fig. 18, Motor Rear

Cover Removal

l Remove the Motor Rear Cover as shown

28
 Lifting
Hook M12

Motor
Startor

Fig. 19 Motor stator removal and assembly

l Assemble the Lifting Hook M12 in the Motor Leg holes at opposite.
Hold the Stator in the Crane. Pull the Motor Stator as shown.

IMPORTANT: Use proper crane having capacity more than 200

Kgs. Hold the stator with proper Hook at evenly.

Special Tool
Drg. No. 07 04 05600
Rotor
Fig. 20 Rotor removal

l Remove M16 Adaptor (Motor Fan shaft) which is at end of Rotor

l Hold the Rotor in the Crane using Nylon flat belt. Use the special
tool (Drg No. 070405600). Tighten both M16 Bolts of special tool
uniformly so that ½ round each bolt and repeat. Rotor will remove
from Crankshaft taper.

DANGER
DANGER : Properly hold the Rotor in the Crane.
Rotor will come out suddenly during removal.

10.5. Crankshaft Disassembly l Remove the end cover bolts (Item 11). Screw the M10 Bolt in the
(Refer Fig. 27 for parts list) end cover thread which was provided for removal (refer
Fig – 10 & 11). Remove the Free end first. Then, remove the Fly
end cover along with Crankshaft.

29
1 1 . C L E A N I N G ,
INSPECTION A N D
R E P A I R I N G

IMPORTANT: Do not use caustic cleaners on the aluminum pistons.

The manufacturer recommends a hot tank inhibited alkaline cleaner
on the aluminum pistons.

Clean all other serviceable metal parts to facilitate inspection. After

the parts have been cleaned, they MUST BE completely dried. Use
a low pressure jet of clean, dry air to blow the parts dry.

IMPORTANT: All gaskets, rubber parts, copper washers, self locking

hardware and circlips ARE TO BE SCRAPPED. ONLY NEW
Manufacturer recommended parts are to be used in place of the
scrapped parts during the assembly procedure to permit the best fit
and performance. Replace the items based on the inspection

12. A S S E M B L Y
IMPORTANT: Refer the Torque chart and apply proper value as
specified

12.1. Compressor block l Assemble the Crankshaft with Fly end cover and then Free
assembly
End cover.

l Assemble the Piston

l Insert the Piston Rings in the piston groove

l Assemble the Cylinder. Use special tool for Ring assembly.

l Assemble the Valves & Cylinder Head

l Assembly the Compressor side Mounting Bracket

l Assemble the Breather Valve

l Assemble the Suction Pipe & Delivery Pipe

l Assemble the Fan. Use the shaft locking method (as indicated
vide para 10.3) to arrest shaft rotation during tightening Left
Hand Nut M16.

30
 12.2. Cooler & Pipelines l Place the cooler, fan guard and Fan cover together in the
assembly ( Refer figure 26 for location. Insert the Crankcase side support bolts and cooler
parts list) side support bolts. Keep these bolts in loose condition.

l Keep the cooler in straight at horizontal position. Insert the

cooler side pipe bolts and tighten fully. Then, tighten the
support bracket bolts.

l Assemble the Pipes (Item 19 & 20)

l Assemble the Safety valve & Drain valve

IMPORTANT: Use Loctite Hi-Tack Gasket sealant for all pipe line
gaskets.

Crankcase side
support bolt

Cooler side
pipe bolt

Cooler side
support bolt

Figure 21 & 22

12.3. Motor assembly (Refer l Assembly the Rotor in the Crankshaft. Insert stud (Item 5) and
figure 25 for part list) Fan shaft (Item 6). Tighten and apply Torque as specified

l Assemble Stator. Refer Figure-19 for assembly. Tighten the Nuts

M10 (Item 4) uniformly at four sides.

31
 l Place the Bearing Cap guide tool (Stud M6 x 150) as shown and
assemble the Motor Rear cover. Ensure the Grease port matches
properly.

l Assemble the Bearing outer Cap with Oil seal and remove the
guide tool. Ensure the Grease port orientation in properly.

l Assemble the Motor Fan and apply specified Torque. Assemble

the Motor Fan cover

Bearing Cap guide

tool (stud M6 x 150)

Figure-23, Motor Rear cover assembly

l Assembly the Motor Side Mounting Bracket. Apply specified

Torque.

l Assemble the Wire rope isolators (Item 19 & 23) and apply
specified Torque.

NOTICE
Apply loctite - 574 for motor joints as indicated
in motor exploded view (Fig.34)

IMPORTANT: Use only 12.9 Grade Screw for Wire Rope Isolator.

32
13. RESTARTING THE l Assembly the Motor Side Mounting Bracket. Apply specified
COMPRESSOR AFTER
L O N G P E R I O D
l Drain the compressor oil from the crankcase and clean the sump.

l Pour in about 3.6 liters of fresh SERVO PRESS 150 oil into the
sump through the overfilling port on the RH side of Crankcase.
l Remove the Suction Manifold and pour little oil in the suction of
LP valves
l Start the compressor and run the compressor in no load condition
for 30 minutes and observe for any abnormal noise or over
heating.

14. TORQUE VALUES

The following torque limits are recommended when tightening the
nuts and bolts on the compressor.

TORQUE CHART
Bolt size Application / Loaction Value

M8 Bolt & Nut General 20 ft-lbs (27 N-m)

M8 Soc. Head Screw Wire rope isolator 20 ft-lbs (27 N-m)

M10 Bolt & Nut End cover, cooler support in crankcase 28 ft-lbs (38 N-m)

M10 Bolt & Nut Cooler pipe line, copper pipe line 20 ft-lbs (27 N-m)

M 10 Stud Motor flange 28 ft-lbs (38 N-m)

M 12 Bolt & Nut Cylinder head, suction & delivery pipe, motor side bracket 44 ft-lbs (60 N-m)

M 16 Stud & Nut Motor rotor locking, Compressor fan shaft 90 ft-lbs (122 N-m)

M 16 Bolt Compressor side Mounting Bracket 100 ft-lbs (134 N-m)

33
15.TOOLS LIST FOR
C O M P R E S S O R

Pos No DESCRIPTION QTY DRG No.

SPECIAL TOOLS

1 MOTOR REMOVING TOOL 1 07 04 0560 0

2 BEARING CAP GUIDE – STUD M6X157 1 10 04 0010 0

3 CRANKSHAFT LOCKING BOLT M10X50 1 0009 06 149

4 RING INSERT DIA 60 1 00 04 1523 0

5 RING INSERT DIA 90 1 02 04 8911 0

6 TORGUE WRENCH 20 – 100 LB-FT 1

STANDARD TOOLS

7 ADJUSTABLE SPANNER 12” 1

8 ALLEN KEY 6mm 2

9 RING SPANNER – 12 X 13 1

10 RING SPANNER – 16 X 17 1

11 RING SPANNER – 18 X 19 1

12 DOUBLE END SPANNER – 10 X 11 1

13 DOUBLE END SPANNER – 12 X 13 1

14 DOUBLE END SPANNER – 16 X 17 1

15 DOUBLE END SPANNER – 18 X 19 1

16 DOUBLE END SPANNER – 24 X 26 1

17 EXTENSION ROD 2” 1

18 EXTENSION ROD 4” 1

19 BOX SPANNER 13, 16, 18 Each 1

34
16.RECOMMENDED
S P A R E S
RECOMMENDED SPARES LIST FOR AOH
KIT PART No. 07 24 1387 9 Consists of Following items

Pos No DESCRIPTION QTY DRG No.

2 GASKET, HEAD DIA 90 4 07 04 0497 0

5 GASKET, FILTER 1 07 04 0498 0

21 GASKET, COOLER PIPE 5 07 04 0544 0

6 GASKET, FLY END COVER 1 07 04 0490 0

7 GASKET, FREE END COVER 1 07 04 0499 0

10 SEAL OIL B50 X 72 X12 2 00 04 2036 0

15 CIRCLIP INTERNAL 6 00 09 17 218

16 # GASKET C-CASE TO CYLINDER 0.75mm 3 07 04 0500 C

GASKET C-CASE TO CYLINDER 0.4mm 3 07 04 0500 B

GASKET C-CASE TO CYLINDER 0.25mm 3 07 04 0500 A

23 GASKET BIG, DISC VALVE 100DIA 4 07 04 0501 0

24 GASKET SMAL,L DISC VALVE 100DIA 2 07 04 0502 0

25 DISC VALVE DIA 100 ASSY 2 A07 0541

27 GASKET BIG, DISC VALVE 60DIA 2 07 04 0503 0

28 GASKET SMALL, DISC VALVE 60 1 07 04 0504 0

29 DISC VALVE DIA 60 ASSY 1 A07 0540

31 PACKING RING 17X22X2 1 00 05 2186 0

33 PACKING RING 21X25X2 1 00 05 2196 0

35 GASKET, BREATHER 1 07 04 0574 0

39 BREATHER VALVE ASSY 1 A02 0462

BREATHER DIAPHRAGM 1 02 04 9432 0

DRAIN VALVE SEAT 1 00 05 1993 0

4.2 FILTER ELEMENT 1 07 04 0637 0

2 RING PERMA-SEAL DIA 90 4 07 04 0509 A

3 RING OIL 3-PIECE DIA 90 4 07 04 0511 A

2 RING PERMA-SEAL DIA 60 2 07 04 0512 A

3 RING OIL 3-PIECE DIA 60 2 07 04 0514 A

30 GASKET COMP - MOTOR 1 07 04 0631 0

# - Suitable thickness to be used to maintain TDC clearance
35
17. P A R T S L I S T

36
37
Fig. 24 G.A. Drawing of Compressor Package
38
Note :
1) Apply loctite 262 before assembly
2) Apply torque of 90 ft-lbs (Stud, motor shaft)

Fig.25 Compressor Package - S07 075

17.1 Compressor Package - S07 075

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

1 RR15070 UNIT 1 X07 0102

2 MOTOR ASSY 1 07 04 0586 0

3 SPRING WASHER M10 4 00 09 96 110

4 HEX NUT M10 4 00 09 48 010

5 STUD, MOTOR SHAFT 1 07 04 0584 0

6 FAN SHAFT, MOTOR END 1 07 04 0576 0

7 WASHER, MOTOR FAN 1 07 04 0640 0

8 SPRING WASHER M16 5 00 09 96 116

9 HEX NUT M16 1 00 09 48 016

10 FILTER, SUCTION 1 07 03 0713 0

11 BOLT HEX HEAD M16X35 5 00 09 06 213

12 BRACKET, COMP SIDE 1 07 03 0717 0

13 BRACKET, MOTOR SIDE 2 07 03 0716 0

14 BOLT HEX HEAD M12X60 4 00 09 06 189

15 PLAIN WASHER M12 4 00 09 96 012

16 SPRING WASHER M12 5 00 09 96 112

17 HEX NUT M12 4 00 09 48 012

18 FOOT REST, MOTOR SIDE 1 07 04 0572 0

19 BOLT HEX HEAD M12X30 1 00 09 06 183

20 WIRE ROPE ISOLATOR, MOTOR SIDE 2 07 04 0579 0

21 WIRE ROPE ISOLATOR, COMP SIDE 2 07 04 0578 0

22 SOC HEAD CAP SCREW M8X45 -12.9 Grade 12 00 09 85 388

23 SPRING WASHER M8 28 00 09 96 108

24 HEX NUT M8 52 00 09 48 008

25 COVER, COOLER 1 07 03 0786 0

26 PLAIN WASHER M8 16 00 09 96 008

27 BOLT HEX HEAD M8X25 4 00 09 06 116

28 * HOSE ASSEMBLY 1 07 03 0121 0

29 * SOC HEAD CAP SCREW M8X55 –12.9 Grade 12 00 09 85 390

30 GASKET, COMP - MOTOR 1 07 04 0631 0

* Not shown in the drawing

39
40
Fig. 26 Compressor Unit (Part No. X070102)
Fig. 17.2 Compressor Unit (Part No. X070102)

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

1 TOP BLOCK RR15070 1 X07 0101

2 GASKET, HEAD DIA 90 4 07 04 0497 0
3 DELIVERY PIPE, LP 1 07 03 0704 0
4 SUCTION MANIFOLD 1 07 03 0720 0
5 GASKET, FILTER 1 07 04 0498 0
6 SPRING WASHER M12 1 2 00 09 96 112
7 BOLT HEX HEAD M12 X 30 8 00 09 06 183
8 BRACKET, COOLER 2 07 04 0573 0
9 SPRING WASHER M10 20 00 09 96 110
10 BOLT HEX HEAD M10X25 20 00 09 06 144
11 FAN SHAFT, COMP SIDE 1 07 04 0577 0
12 KEY, WOODRUFF 1 07 04 0565 0
13 FAN ASSY, COMPRESSOR 1 A07 0507
14 SPRING WASHER M16 1 00 09 96 116
15 HEX NUT M16 LEFT HAND 1 07 04 0585 0
16 SCREW CRUB SOC HEAD M8X12 1 00 09 87 742
17 GUARD, FAN 1 07 03 0710 0
18 COOLER, INTER CUM AFTER 1 07 03 0696 0
19 PIPE ASSY I/C TO HP 1 07 04 0575 0
20 PIPE ASSY HP TO A/C 1 07 04 0583 0
21 GASKET, COOLER PIPE 5 07 04 0544 0
22 PLAIN WASHER M10 8 00 09 96 010
23 HEX NUT M10 2 00 09 48 010
24 SAFETY VALVE ASSY 3/8" BSP 1 A02 0002
25 DRAIN VALVE 1/4" BSP, I/C 1 A02 0045
26 FOOT REST, COMP SIDE 2 07 04 0571 0
27 BOLT HEX HEAD M12X60 4 00 09 06 189
28 HEX NUT M12 4 00 09 48 012
29 NAME PLATE 1 07 04 0636 0
30 RIVET, NAME PLATE 4 00 04 6454 A
31 COVER, FAN 1 07 03 0807 0
32 Ermeto 1/4” x 1/4” BSP 2 00 04 2658 A
33 Pipe Assy, Breather 1 07 04 0722 0
34 NIPPLE, HOSE ASSY 1 07 04 0641 0

* Not shown in the drawing

41
42
Fig. 27 Compressor Block (Part No. X070101)
Fig. 17.3 Compressor Block (Part No. X070101)

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

1 CRANK CASE, RR15070 1 07 03 0697 0

2 STUD M12X45 8 00 05 1456 0

3 STUD M12X54 7 00 05 1455 0

CRANK SHAFT WITH BEARING (Consist 4 & 5) 1 A07 0530

4 CRANK SHAFT ASSY 1 ——

5 BEARING 6310 2 ——

6 GASKET, FLY END COVER 1 07 04 0490 0

7 GASKET, FREE END COVER 1 07 04 0499 0

8 COVER, FLY END 1 07 03 0712 0

9 COVER, FREE END M/C 1 07 03 0703 0

10 SEAL OIL B50 X 72 X12 2 00 04 2036 0

11 BOLT HEX HEAD M10X20 14 00 09 06 143

12 SPRING WASHER M10 14 00 09 96 110

13 PISTON ASSY DIA 90 2 07 04 0507 0

14 PISTON ASSY DIA 60 1 07 04 0508 0

15 CIRCLIP INTERNAL 6 00 09 17 218

16 # GASKET C-CASE TO CYLINDER 0.75mm 3 07 04 0500 C

GASKET C-CASE TO CYLINDER 0.4mm 3 07 04 0500 B

GASKET C-CASE TO CYLINDER 0.25mm 3 07 04 0500 A

17 CYLINDER, DIA90 DV 2 07 03 0611 0

18 CYLINDER DIA 60 DV 1 07 03 0614 0

19 SPRING WASHER M12 24 00 09 96 112

20 HEX NUT M12 24 00 09 48 012

21 STUD M12X60 6 00 05 2013 0

22 STUD M12X75 2 00 05 2014 0

23 GASKET BIG, DISC VALVE 100DIA 4 07 04 0501 0

24 GASKET SMAL,L DISC VALVE 100DIA 2 07 04 0502 0

25 DISC VALVE DIA 100 2 A07 0541

# - Suitable thickness to be used to maintain TDC clearance

43
44
Fig. 27 Compressor Block (Part No. X070101)
Fig. 17.3 Compressor Block (Part No. X070101)

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

26 CYLINDER HEAD 90 DV 2 07 03 0617 0

27 GASKET BIG, DISC VALVE 60DIA 2 07 04 0503 0

28 GASKET SMALL, DISC VALVE 60 1 07 04 0504 0

29 DISC VALVE DIA 60 1 A07 0540

30 CYLINDER HEAD 60 DV 1 07 03 0783 0

31 PACKING RING 17X22X2 1 00 05 2186 0

32 DRAIN PLUG 1 A02 0033

33 PACKING RING 21X25X2 1 00 05 2196 0

34 DIPSTICK WITH CHAIN 1 A07 0075

35 GASKET, BREATHER 1 07 04 0574 0

36 BREATHER HOUSING 1 07 04 0569 0

37 SPRING WASHER M8 2 00 09 96 108

38 BOLT HEX HEAD M8X20 2 00 09 06 115

39 BREATHER 1 A02 0462

40 STUD M12 X 70 1 00 05 1883 0

41 Nipple 1” (m) x 1/2” (f) 1 07 04 0721 0

# - Suitable thickness to be used to maintain TDC clearance

45
Fig. 28 Motor Assembly (Part No. 07 04 0586 0)

46
Fig. 17.4 Motor Assembly (Part No. 07 04 0586 0)

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

1 MOTOR 15HP, 415V, 4P 1 10 * 404043

2 STUD M10 X 47 4 00 04 5363 0

47
Fig. 29 Filter Assembly (Part No. 07 03 0713 0)

48
Fig. 17.5 Filter Assembly (Part No. 07 03 0713 0)

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

1 FILTER HOUSING 1 07 03 0781 0

2 SPRING WASHER M6 4 0009 96 106

3 HEX BOLT M6 X 16 4 0009 06 084

4 FILTER KIT (CONSIST 4.1 - 4.6) 1 07 04 0644 0

4.1 PLATE & PIPE ASSY 1 07 04 0638 0

4.2 FILTER ELEMENT 1 07 04 0637 0

4.3 FILTER COVER 1 07 04 0639 0

4.4 SPECIAL PLAIN WASHER M10 1 ——

4.5 NUT NYLOC HEX M8 1 ——

4.6 GASKET 1 ——

49
Keep the “PIP” mark
in top during assy

Rail opening & spacer opening

should be at 90 Deg difference
approximately

Fig. 30 PISTON ASSEMBLY DIA 90 – 07 04 0507 0

50
Fig. 17.6 PISTON ASSEMBLY DIA 90 – 07 04 0507 0

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

1 PISTON DIA 90 WITH G.PIN 1 07 04 0505 0

2 RING PERMA-SEAL DIA 90 2 07 04 0509 A

3 RING OIL 3-PIECE DIA 90 2 07 04 0511 A

51
 Keep the “PIP” mark in top
during assy

Rail opening & spacer opening

should be at 90 Deg difference
approximately

Fig. 31 Piston Assembly Dia 60 (Part No. 07 04 0508 0)

52
Fig. 17.7 Piston Assembly Dia 60 (Part No. 07 04 0508 0)

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

1 PISTON DIA 60 WITH G.PIN 1 07 04 0506 0

2 RING PERMA-SEAL DIA 60 2 07 04 0512 A

3 RING OIL 3-PIECE DIA 60 2 07 04 0514 A

53
Fig. 32 BRAETHER VALVE ASSEMBLY – A02 0462

Fig. 33 DRAIN VALVE ASSEMBLY – A02 0045

54
Fig. 17.8 BRAETHER VALVE ASSEMBLY – A02 0030

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

-1 Breather top 1 02 04 9424 0

2 Breather Strainer 1 02 04 9433 0

3. Breather bottom 1 02 04 9425 0

4. Breather disc 1 02 04 9432 0

Fig. 17.9 DRAIN VALVE ASSEMBLY – A02 0045

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

1 HOUSING 1 00 04 2187 0

2 CONE SEAT 1 00 05 1471 0

3 VALVE SEAT 1 00 05 1993 0

4 PIN 1 00 05 2512 0

55
56
57
58
59
60
18. Operating instruction and maintenance manual for motor

Model : EC 160 X
COMPRESSOR MOTOR (MONO COUPLED)
Fitted in E.M.U Coaches having 415 V AC SYSTEM

Manufactured by:
Elgi Electric & Industries Limited
Tamaraikulam post,Pollachi.
Coimbatore -642109

61
62
SI.No. Description Page No

1 General description ................................................................................................. 51

2. Technical specification ............................................................................................ 51

3. Winding data ............................................................................................................ 52

4. Maintenance ............................................................................................................. 52

5. Service Instruction ................................................................................................... 53

6. Parts list .................................................................................................................... 54

7. Exploded view .......................................................................................................... 55

8. Tool list ...................................................................................................................... 56

63
64
G E N E R A L
D E S C R I P T I O N

Mono coupled AC motor, Model EC 160 X, specially designed for

Elgi compressor, confirming to RDSO specification E-10/3/09, to meet
the requirements of the rolling stock application.

Magnetic circuit consists of electrical steel laminations pressed to

form a core pack which is wound with copper wire. The Die cast
rotor is pressed with hollow shaft .The laminated stampings is made
out of best quality electrical grade silicon steel.

All the rotating parts are dynamically balanced to minimize vibration

at the highest allowed speed, thus ensuring smooth running and
increase in the life of bearing.

The stator winding is impregnated under vacuum with the best quality
of insulating varnish to obtain good insulation resistance through
out service condition.

65
T E C H N I C A L D ATA

Frame EC160X

Out put 11 KW

Voltage 415 +/-10% V AC

Current 20.0 A

Frequency 50 Hz

Speed 1460 rpm

Pole 4

Phase 3

Insulation Class - H

Rating S1

Enclosure IP - 57 S

Conductor covering Dual coated enamel

as per IS:13730 – PT.13

Connection Star

Direction of rotation ACL from non drive end

Type of cooling Fan cooled

Specification RDSO-E-10/3/09 & RDSO/PE/TP/EMU/0014

Ambient 65 deg.C

Weight 137 kg

Dimensional drawing No. U0718

Lubricant Servogem- RR3

Bearing-NDE side 6309 - C3

66
W I N D I N G D A T A

Size of conductor : 4x1.12 mm

Conductor covering : Dual coated enamel as per IS:13730-P13

Type of winding : Lap

Number of layers : 2

Numbers of turn /coil : 8

Winding pitch : 1-9

NO. Of slots Stator/Rotor : 36/28

Stack length : 220 mm

Connection : Star

Rotor construction : Die cast

Resistance at 25O C : 0.350 Ohm

67
M A I N T E N A N C E

Weekly
l Check for any loose connections in motor terminals.

l Check for abnormal sound.

Half yearly
l Check the temperature of the body and the bearing on load.

l Re grease the bearing with Servogem- RR3 grease.

l Check the insulation resistance and make it sure, it should be more than one meg.-ohm

l Repeat weekly maintenance.

68
S E R V I C E
I N S T R U C T I O N S

DISMANTLING PROCEDURE
l Disconnect the power.

l Dismantle the fan cover by loosing the M6 Hex. Bolt.

l Dismantle the fan loosing the Hex Nut M16 (Item No. 02). \

l Follow the instruction as given at Para 10.4

CHECKING INSTRUCTION
l Test the insulation resistance of the stator winding.

l Check the bearing, if needed replace by new one. If bearing is found OK,
replenish with fresh grease.

l Check the oil seal (item No. 9) and replace if required

ASSEMBLY PROCEDURE
l Follow the instruction given in Para 12.3

l Fix the fan cover on rear cover by M6 hex. Screw.

l Assemble the terminal box in position and connect the leads as indicated in ferrules.

PRECAUTIONS TO BE TAKEN WHILE SERVICING

l During dismantling use proper tools only.

l Bearing should be removed and assembled by strictly. following the

recommendation of bearing manufacturers
l Take special precaution while handling wound components, so that they are not damaged.

l If re impregnation is needed use recommended varnish only and strictly follow the
procedure as advised by the varnish manufacturers.

l If drying of winding is needed follow the approved method only.

l Hose proof packing should be properly maintained.

l All joint should be applied with gasketing loctite - 574

69
E X P L O D E D
V I E W - M O T O R

Figure: 34, Motor Exploded View

70
P A R T S L I S T

SI.No Description Qty Drg/Part No.

1 FAN COVER 1 3FAU01240000

2 HEX NUT M16 1 Refer ELGI part

3 WASHER, MOTOR FAN 1 Refer ELGI part

4 FAN SHAFT, MOTOR END 1 Refer ELGI part

5 KEY 1 3RTE19420000

6 FAN, MOTOR 1 3NAW07450000

7 BEARING CAP OUTER 1 3FAE19300000

8 OIL SEAL 1 1 LAN00570000

9 REAR COVER 1 1BCA00010000

10 BALL BEARING NSK 6309-C3 1 3FAE19210000

11 BEARING CAP INNER 1 3RTW03730000

12 ROTOR ASSEMBLY 1 5200LW033300

13 BODY WITH STATOR ASSY 1 3PDW0060000

14 “O” RING DIA6 X 2 1 1JXX0002000

15 HEX. SCREW M6X8 1 2EMF0044Y000

16 GASKET 1 3RNW08120000

17 TERMINAL BOX 1 3FCW08080000

18 CABLE GLAND - M32 X 1.5 P 1 1HAA00040000

19 TERMINAL BOARD 1 3PEW03760000

20 GASKET 1 3RNW08110000

21 TERMINAL BOX COVER 1 3PEW08100000

22 GASKET LOCTITE -574 50 ml 4PAG00140000

71
T O O L S L I S T
F O R M O T O R

Sl.No. Parts Spanner size

1. Fan cover (M6) 10 – 11

2. Grease nipple (M10) 10 - 11

3. Fan nut (M16) 24 - 27

4. Bearing cap (M6) 10 - 11

5. Rear cover (M8) 12 - 13

6. Bearing Puller 3 lug puller

7. Eye bolt (M12) 18 - 19

8. Earth screw (M6) 10 - 11

9. Terminal cover (M6) 10 -11

72
73
ELGI EQUIPMENTS LIMITED
Singanallur, Coimbatore, TN - 641 005, INDIA.

Tel : Domestic : 0091 - 0422 - 2589555

International : 0091 - 422 - 2589555

Fax : Domestic : 0091 - 0422 - 2573697

International : 0091 - 422 - 2576849

e-mail : Domestic : info@elgi.com

International : export@elgi.com

Document Ref. No. : 07 90 07 020

Revision Status

R00 - First Edition : December 2005

R01 - First Revision : September 2007

Printed in India.

PRICE : INR. 750.00

Compiled by

ENGINEERING DEPARTMENT,
RAILWAY & OE

Approved & Issued by

RESEARCH & DEVELOPMENT DEPARTMENT

Reciprocating Air Compressor
(Electric Powered)
For EMU Applications

OPERATION, MAINTENANCE
MANUAL AND PARTS LIST

Model : RR 15 070

ELGI EQUIPMENTS LIMITED

SINGANALLUR,
COIMBATORE - 641 005. INDIA.
76