Atlas Copco XAHS 447 Cd S3A APP, Instruction Manual

Page 1: ...3A APP XAMS 1150 CD7 T3 APP XATS 487 Cd S3A APP XATS 1050 CD7 T3 APP XAHS 447 Cd S3A APP XAHS 950 CD7 T3 APP XAVS 407 Cd S3A APP XAVS 900 CD7 T3 APP Instruction Manual for Portable Compressors English Engine CAT C9 ...

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Page 3: ...ABLE ENERGY DIVISION www atlascopco com Printed matter N 2954 5440 02 07 2013 Instruction Manual for Portable Compressors XAMS 527 XAMS 1150 XATS 487 XATS 1050 XAHS 447 XAHS 950 XAVS 407 XAVS 900 Original instructions ...

Page 4: ...er s approval in writing Neglecting maintenance or making changes to the setup of the machine can result in major hazards including fire risk While every effort has been made to ensure that the information in this manual is correct Atlas Copco does not assume responsibility for possible errors Copyright 2013 Atlas Copco Airpower n v Antwerp Belgium Any unauthorized use or copying of the contents o...

Page 5: ... 3 2 Electric system 22 3 2 1 Circuit diagram index 22 3 3 Markings and information labels 29 4 Operating instructions 30 4 1 Parking towing and lifting instructions 30 4 1 1 Parking instructions Wagon 30 4 1 2 Towing instructions Wagon 31 4 1 3 Towbar levelling Wagon 31 4 1 4 Lifting instructions 32 4 2 Internal lighting 32 4 3 Preheater option 32 4 3 1 Description heating operation 32 4 3 2 Oper...

Page 6: ...lement and the safety cartridge 77 6 2 4 Air receiver 78 6 2 5 Safety valve 78 6 3 Fuel system 78 6 3 1 Priming instructions 78 6 3 2 Replacing filter elements 79 6 3 3 Cleaning crankcase breather filter 79 6 4 Brake adjustments 80 6 4 1 Brake shoe adjustment no ABS 80 6 4 2 ABS braking system 80 6 4 3 Brake adjustment wagon ABS 81 6 4 4 Brake adjustment wagon without ABS 82 6 4 5 Brake adjustment...

Page 7: ...ponents Skill level 3 Electrical technician An electrical technician is trained and has the same qualifications as both the operator and the mechanical technician In addition the electrical technician may carry out electrical repairs within the various enclosures of the unit This includes work on live electrical components Skill level 4 Specialist from the manufacturer This is a skilled specialist...

Page 8: ...equipment shall be kept clean i e as free as possible from oil dust or other deposits 7 To prevent an increase in working temperature inspect and clean heat transfer surfaces cooler fins intercoolers water jackets etc regularly See the Preventive maintenance schedule 8 All regulating and safety devices shall be maintained with due care to ensure that they function properly They may not be put out ...

Page 9: ...p the safety break away cable or safety chain If the unit has no parking brake or jockey wheel immobilize the unit by placing chocks in front of and or behind the wheels When the tow bar can be positioned vertically the locking device must be applied and kept in good order The unit must always be used parked stored in a non publicly accessible area locked away from access by unauthorized persons 6...

Page 10: ...common compressed air system fit an appropriate non return valve check valve between compressor outlet and the connected sand blasting or compressed air system Observe the right mounting position direction 11 Before removing the oil filler plug ensure that the pressure is released by opening an air outlet valve 12 Never remove a filler cap of the cooling water system of a hot engine Wait until the...

Page 11: ... supervision of someone qualified for the job 1 Use only the correct tools for maintenance and repair work and only tools which are in good condition 2 Parts shall only be replaced by genuine Atlas Copco replacement parts 3 All maintenance work other than routine attention shall only be undertaken when the unit is stopped Steps shall be taken to prevent inadvertent starting In addition a warning s...

Page 12: ...hin the machine or driver Check the direction of rotation of electric motors when starting up the machine initially and after any alteration to the electrical connection s or switch gear to check that the oil pump and the fan function properly 20 Maintenance and repair work should be recorded in an operator s logbook for all machinery Frequency and nature of repairs can reveal unsafe conditions 21...

Page 13: ...he technical specifications Safety reasons prohibit any other applications 3 National legislation requirements with respect to re inspection must be complied with 4 No welding or heat treatment of any kind is permitted to those vessel walls which are exposed to pressure 5 The vessel is provided and may only be used with the required safety equipment such as manometer overpressure control devices s...

Page 14: ... by the engine drives the female rotor The compressor delivers pulsation free air Injected oil is used for sealing cooling and lubricating purposes Compressor oil system The oil is boosted by air pressure The system has no oil pump The oil is removed from the air in the air oil vessel at first by centrifugal force secondly by the oil separator element The vessel is provided with an oil level indic...

Page 15: ...essor has a towbar with parking brakes For available options see chapter Available options Bodywork The bodywork has openings for the intake and outlet of cooling air and hinged doors for maintenance and service operations The bodywork is internally lined with sound absorbing material Lifting beam A lifting beam is accessible when a small door at the top is opened Control panel The control panel g...

Page 16: ...in parts ETS CE OFce AFe FFpc FFc OFe BH TB IC SN ES AFS F A E FT FLS FFac FCft F1 CBE FPco DPar DPce OLG DPeo DPoc DPr RS H AR MPV FL CP CU RV FLG ES LV AOV ATS WPS SV AFce R EP FCc CLS CT CY OC CB B BS RPS ...

Page 17: ... Cooler DPr Drain Plug Radiator E Engine EP Exhaust Pipe Reference Name ES Emergency Stop ETS Element Temperature Sensor F Fan F1 Fuse FCft Filler Cap fuel tank FCc Filler Cap coolant FFac Fuel Filter AC FFpc Fuel Prefilter Caterpillar FFc Fuel Filter Caterpillar FL Flash Light FLG Fuel Level Gauge FLS Fuel Level Sensor FPco Filler Plug oil compressor element FT Fuel Tank H Horn IC Intercooler LV ...

Page 18: ... Air Filter engine AFS Air Filter Switch AOV Air Outlet Valves AR Air Receiver BOV Blow Off Valve BVof Bypass Valve oil filter C Coupling CBE Cubicle for Electrical devices CE Compressor Element CU Control Unit CV Check Valve CY Cylinder EC DP Drain Plug E Engine F Fan F1 Fuse FPco Filler Plug oil compressor element FR Flow Restrictor LV Loading Valve MPV Minimum Pressure Valve OC Oil Cooler OFce ...

Page 19: ...il stop valve OSV prevents the oil from flowing back into the compressor element The thermostatic by pass valve TBV starts opening when the oil temperature is 80 C 176 F The compressor element has an oil gallery in the bottom of its casing The oil for rotor lubrication cooling and sealing is injected through holes in the gallery Lubrication of the bearings is ensured by oil injected into the beari...

Page 20: ... 20 CONTINUOUS PNEUMATIC REGULATING SYSTEM VH TS PS OSV OC CV CE TS BOV UA WPS AR OS MPV FR SL RV AFce TBV BVof OFce TV ...

Page 21: ...imum load speed and unloading speed the output of a screw compressor is proportional to the rotating speed 2 Air inlet throttling If the air consumption is equal to or exceeds the maximum air output the engine speed is held at maximum load speed and the throttle valve TV is fully open If the air consumption is less than the maximum air output air receiver pressure increases and the regulating valv...

Page 22: ...PS1 Pressure switch Air filter 05 3 PT1 Pressure sensor Vessel pressure Machine 05 2 PT2 Pressure sensor Regulating pressure Machine 05 3 PT3 Pressure sensor Oil Stop valve pressure Machine 05 4 PT4 Pressure sensor Interstage pressure Machine 05 5 PT5 Pressure sensor Air discharge pressure Optional 06 5 Q1 Circuit breaker 15A Main Machine 03 8 Q13 Circuit breaker 60A Alternator Machine 03 2 Q2 Cir...

Page 23: ...Optional 07 7 X3 Connector XC3003 4003 Remote 06 8 X5 Connector Engine diagnostic Machine 03 6 Y1 Solenoid Loading valve Machine 05 3 Y2 Solenoid Blow down valve Machine 05 4 Y3 Solenoid Air shut off valve Optional 06 3 Y4 Solenoid Etherstart Optional 06 5 Wire size Colour code a 1 mm2 0 black b 1 5 mm2 1 brown bx 1 5 mm2 NSGAFOÜ 2 red c 2 5 mm2 3 orange cx 2 5 mm2 NSGAFOÜ 4 yellow d 4 mm2 5 green...

Page 24: ... 24 SH 03 ENGINE CIRCUIT 1 2 3 5 9 8 7 6 G 4 10 A B C D E F 9822 0963 49 ...

Page 25: ... 25 SH 04 CONTROL MODULE 1 2 3 5 9 8 7 6 4 10 A B C D 9822 0963 49 ...

Page 26: ... 26 SH 05 COMPRESSOR CIRCUIT 1 2 3 5 9 8 7 6 G 4 10 A B C D E F 9822 0963 49 ...

Page 27: ... 27 SH 06 OPTIONAL EQUIPMENT 1 2 3 5 9 8 7 6 G 4 10 A B C D E F 9822 0963 49 ...

Page 28: ... 28 SH 07 OPTIONAL EQUIPMENT 1 2 3 5 9 8 7 6 4 10 A B C D E 9822 0963 49 ...

Page 29: ...arning Part under pressure Do not stand on outlet valves Start Stop indication of switch Do not run the compressor with open doors Lifting permitted Use diesel fuel only 4 bar 58 psi Tyre pressure 6 bar 87 psi Tyre pressure Sound power level in accordance with Directive 2000 14 EC expressed in dB A Fork lifting permitted Don t lift here Read the instruction manual before lifting Filler cap coolant...

Page 30: ...nated wind streams and walls Do not obstruct air evacuation from the cooling system Avoid recirculation of exhaust air from the engine This can cause overheating and engine power decrease The operator is expected to apply all relevant Safety precautions Before putting the compressor into use check the brake system as described in section Brake shoe adjustment no ABS After the first 100 km travel C...

Page 31: ...ck on the brakes by pulling button 3 TOWBAR LEVELLING WAGON The towbar of the wagon is equipped with an adjustable spring loaded levelling device To adjust 1 Slide back the rubber bellows 1 2 Turn the nut 2 clockwise to increase the spring load for lifting the towbar turn the nut 2 counter clockwise to decrease the spring load for lowering the towbar 3 Slide the bellows 1 over the nut Before towin...

Page 32: ... will switch between three levels LARGE SMALL and OFF control interval The temperature thresholds have been fixed programmed in the electronic control device If the heat requirement at level SMALL is so low that the cooling water temperature reaches 85 C 185 F the device goes into control interval This is followed by the fan continuing to run for about 130 sec The signal lamp will stay lit during ...

Page 33: ... is deactivated after the set heating period has ended It has to be activated again for each new heating action Settings Commisioning After connecting the power all symbols in the display will blink Now the actual time has to be set before the heater can be operated Press button 1 time blinks Set time with buttons 2 or 3 Press button 1 time is displayed colon blinks Setting the time Press button 1...

Page 34: ...htened 3 With the compressor standing level check the level of the engine oil Add oil if necessary up to the upper mark on the dipstick Also check the engine coolant level Consult the Engine Operation Manual for the type of coolant and type and viscosity grade of the engine oil 4 Remove the air receiver drain plug 1 see figure and open the valve to drain possible condensate Close the valve when oi...

Page 35: ...ental conditions Always install the pull relief 2 see figure Inspect hoses and connections daily STARTING STOPPING Safety precautions Make sure the fuel tank is filled up when INTERNAL FUEL is selected No external force may be applied to the air outlet valve s e g by pulling hoses or by connecting equipment directly to the valve s Do not disconnect power supply to control box in any way when the c...

Page 36: ...NEL Reference Name Power off on switch To switch the control panel on and off Start button Pressing this button will start the compressor Stop button Pressing this button will stop the compressor in a controlled way ...

Page 37: ...sing this button you can toggle between Measurements View and Main View Settings View button By pressing this button you can toggle between Settings View and Main View Alarms View button By pressing this button you can toggle between Alarms View and Main View Navigation buttons These buttons are used to navigate through the display menu s Enter button Confirms stores the selection change Back butt...

Page 38: ...receiver 2 Check the air outlet temperature of the compressor element 3 Check the engine oil pressure the coolant temperature and display of control box 4 Avoid the engine running out of fuel Nevertheless if this happens fill the fuel tank and prime the fuel system to speed up starting see section Specific start procedure BATTERY SWITCH The compressor is equipped with a battery switch When the com...

Page 39: ...form a brief selftest Push the start button and the starter motor will automatically try to start the engine 1 2 After cleaning draining the fuel tanks the system is filled with air Before starting the engine operate the fuelpump on the fuelfilter to fill the fuelsystem Loosen the vent screw 1 on the fuel filter Operate the hand pump 2 at the filter until fuel comes out of the bore for the vent sc...

Page 40: ... OVERVIEW ICONS Reference Name 1 Compressor status 2 Vessel pressure indication or info text 3 Compressor info Main View Indication Measuring View Indication Settings View Indication Alarm View Indication ...

Page 41: ...ontroller will show its dedicated icon Reference Name Operation Mode Local Operation Mode Remote Operation Mode PC Control Operation Mode Automatic Operation Mode Automatic Mode is active but the Auto Start and Auto Stop function are both inactive Operation Mode Block Mode Alarm Active not acknowledged Shutdown Alarm Alarm Active not acknowledged Non Shutdown Alarm Alarm Active acknowledged Alarm ...

Page 42: ...e Up and Down navigation buttons to scroll through the full list of settings Use the Enter button to enter the selected submenu Use the Back button to leave the entered sub menu Alarm View Use the Up and Down navigation buttons to scroll through the full list of alarms The DM Lists and the Log Lists can be selected and entered to access the sublist ...

Page 43: ...ill not start The vessel pressure has to be lowered by opening the blow down valve After power up the vessel pressure normally is low enough to proceed with the starting procedure The display now shows The machine is now ready to be started and is waiting for a start command Xc3003 v1 00 0 r7307 If the Power switch is turned to the OFF position while the vessel is blowing down it will not power do...

Page 44: ...tween compressor controller and engine controller is established the machine will preheat according to the parameters of the engine controller Active Buttons Stop Button to cancel Start command Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button Active Buttons Stop Button to cancel Start command Load Button to activate Automatic Load Measurement V...

Page 45: ...g time depends on cranking time The display now shows The engine starts running at idle speed The display shows The engine will run at minimum rpm until the engine s coolant temperature reaches 40 C with a minimum time of 15 seconds and a maximum time of 300 seconds Active Buttons Stop Button to cancel Start command Load Button to activate Automatic Load Measurement View Button Settings View Butto...

Page 46: ...splay shows Active Buttons Stop Button to cancel Start command Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button Active Buttons Stop Button to cancel Start command Load Button to initiate Automatic Load Measurement View Button Settings View Button Alarms View Button ...

Page 47: ...ng the following display is shown default display The controller controls the speed of the engine in order to meet the requested working pressure at the most economical fuel usage Active Buttons Stop Button to cancel Start command Load Button to cancel Load command Measurement View Button Settings View Button Alarms View Button Active Buttons Stop Button to cancel Start command Load Button to canc...

Page 48: ... the machine is shutdown due to a critical alarm or an emergency stop the display will show Active Buttons Start Button to initiate Start command Measurement View Button Settings View Button Alarms View Button Active Buttons Start Button to initiate Start command Measurement View Button Settings View Button Alarms View Button Active Buttons Measurement View Button Settings View Button Alarms View ...

Page 49: ... button If the fuel level is still low the view will change to As soon as the fuel level is higher than the warning level the alarm icon will automatically disappear As long as there is an alarm icon in the middle of the bottom part of the view all active acknowledged un acknowledged alarms can be seen by pressing the Alarm View button Pressing the Alarm View button again will bring you back to th...

Page 50: ...like to change press Enter To change a setting the red figure is editable Scroll up down and press Enter to change Use left right to shift between editable figure Now press Back until you re back in the Main View or in the menu you require Go To Diagnostics Press the Settings View button scroll to 1000 GENERAL SETTINGS press Enter scroll to 1150 DIAGNOSTICS Enter the DIAGNOSTICS menu Enter the ENA...

Page 51: ...e power switch on the control panel must be off Always use the remote control function in accordance to local work area legislation 1 2 3 4 5 The maximum range in the open field is 350 metres with full batteries Obstacles between receiver and control unit should be avoided When using several remote controlled units please take care that there is a distance between two receivers of at least 80 cm ...

Page 52: ...s of Remote Start Stop Load digital inputs The start stop load buttons at the control panel will be inactive and if pressed the display will show To deactivate Remote Operation Press the Settings View button scroll to 1000 GENERAL SETTINGS press Enter scroll to 1100 OPERATION MODE COMMAND press Enter go to parameter SETTINGS press Enter scroll to LOCAL press Enter Now press Back until you are in t...

Page 53: ... Warning Xc 2000 EMERGENCY STOP INPUT Shutdown Xc 2040 REMOTE EMERGENCY STOP Shutdown Xc 2070 COOLANT LEVEL LOW WARNING Warning Xc 2080 COOLANT LEVEL LOW SHUTDOWN Shutdown Xc 2090 P AIRFILTERS HIGH Warning Xc 2100 NO PROJECTFILE DOWNLOADED Warning Xc 2752 NAM OILTRONIX BYPASS CIRCUIT Shutdown After Stop Xc 2762 NAM OILTRONIX CLOSED CIRCUIT Shutdown After Stop Xc 2772 NAM AIRXPERT OPENED CIRCUIT Sh...

Page 54: ...IRCUIT Warning Xc 4150 H P ELEMENT TEMPERATURE ALARM 1 Warning Xc 4160 H P ELEMENT TEMPERATURE ALARM 2 Controlled Stop Xc 4170 H P ELEMENT TEMPERATURE ALARM 3 Shutdown Xc 4190 H P ELEMENT TEMP SENSOR CIRCUIT Shutdown Xc 4220 AFTERCOOLER AIR TEMP SENSOR CIRCUIT Warning Xc 4230 AFTERCOOLER FREEZING DANGER Indication Xc 5200 AIR SHUT OFF Shutdown Xc 6190 CHARGE MONITORING FAIL Indication Xc 6327 STAR...

Page 55: ...ESSURE ECU COOLANT TEMPERATURE ECU COOLANT LEVEL ECU SUPPLY VOLTAGE ECU AMBIENT AIR TEMPERATURE ECU AIR INLET TEMPERATURE ECU FUEL TEMPERATURE ECU OIL TEMPERATURE ECU ENGINE SPEED ECU INJECTOR 1 ECU INJECTOR 2 ECU INJECTOR 3 ECU INJECTOR 4 ECU INJECTOR 5 ECU INJECTOR 6 ECU INJECTOR 7 ECU INJECTOR 8 ECU SOOT LOAD 6981 INLET VALVE POS FAILURE Shutdown Xc 7002 ECU COMMUNICATION Shutdown Xc 7007 ECU R...

Page 56: ...ce Paks at your local Atlas Copco dealer SERVICE KITS A service kit is a collection of parts to fit a specific repair or rebuilding task It guarantees that all necessary parts are replaced at the same time which improves the uptime of the unit The order numbers of the Service Kits are listed in the Atlas Copco Parts List ASL STORAGE Run the compressor regularly e g twice a week until warm Load and...

Page 57: ... Poor maintenance can void any warranty claims MAINTENANCE SCHEDULE COMPRESSOR To determine the maintenance intervals use of service hours or calendar time whichever occurs first Service hours Daily 50 hrs after initial start up Every 250 hrs Every 500 hrs Every 750 hrs Every 1000 hrs Every 2000 hrs Yearly Service parts 2912 4430 05 PAK 2912 4430 06 PAK For the most important subassemblies Atlas C...

Page 58: ... Check for leaks in engine compressor air oil or fuel system x x x x x Check torque on critical bolt connections x x x x Check electrolyte level and terminals of battery x x x x x Check engine minimum and maximum speed x x x x x Replace compressor oil filter s 5 x x x x Inspect Adjust fan belt x x x x x x Adjust engine inlet and outlet valves 2 x x x x x Hoses and clamps Inspect Replace x x x x x ...

Page 59: ...1 x Check functioning of regulating valve x x Test safety valve 9 x x x Replace bleed off valve unloader x x x Check rubber flexibles 11 x x x Clean after cooler option 1 x x x Replace DD PD QD filter option x x x Clean oil stop valve x x x Change compressor oil 1 7 x x x Replace oil separator element x x x Clean fuel cooler x x x Clean crankcase breather filter and check for obstructions x x x Re...

Page 60: ...by pass valve as specified in the parts list 6 Gummed or clogged filters means fuel starvation and reduced engine performance 7 See section Oil specifications 8 The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing points 2913 0028 00 refractometer 2913 0029 00 pH meter 9 See section Safety valve 10 See section Before starting 11 Replace all rubber flexible...

Page 61: ...g of the overrun brake x x x Check brake system if installed and adjust if necessary x x x Oil or grease brake lever and moving parts such as bolts and joints x x x Check Adjust lateral play of wheel bearing x x x Check tyres for uneven wear x x Grease sliding points on height adjusting parts x x Check safety cable for damage x x Check Bowden cable on height adjustable connection device for damage...

Page 62: ...ccumulate in the valve rocker cover area PAROIL releases excess heat efficiently whilst maintaining excellent bore polish protection to limit oil consumption PAROIL has an excellent Total Base Number TBN retention and more alkalinity to control acid formation PAROIL prevents Soot build up PAROIL is optimized for the latest low emission EURO 3 2 EPA TIER II III engines running on low sulphur diesel...

Page 63: ... F 68 F 50 F 40 F 22 F 32 F 14 F 4 F PAROIL S xtreme PAROIL S xtreme PAROIL S PAROIL S Synthetic compressor oil PAROIL S Synthetic compressor oil PAROIL S xtreme Liter US gal Order number can 5 1 3 1630 0160 00 can 20 5 3 1630 0161 00 barrel 210 55 2 1630 0162 00 container 1000 264 1630 0163 00 Liter US gal Order number can 20 5 3 1630 0180 00 barrel 210 55 2 1630 0181 00 ...

Page 64: ...104 F 86 F 68 F 50 F 40 F 22 F 32 F 14 F 4 F PAROIL EXTRA PAROIL E PAROIL EXTRA PAROIL E Synthetic engine oil PAROIL E xtra Mineral engine oil PAROIL E Liter US gal Order number can 5 1 3 1630 0135 00 can 20 5 3 1630 0136 00 Liter US gal Order number can 5 1 3 1615 5953 00 can 20 5 3 1615 5954 00 barrel 210 55 2 1615 5955 00 container 1000 264 1630 0096 00 ...

Page 65: ...el in accordance to the instructions in the Engine Operation Manual and if necessary top up with oil CHECK COMPRESSOR OIL LEVEL With the compressor standing horizontal check the level of the compressor oil The pointer of the oil level gauge 1 must register in the upper extremity of the green range Add oil if necessary Before removing the oil filler plug 2 ensure that the pressure is released by op...

Page 66: ...s until the pressure is released through the automatic blow down valve Make sure that all pressure is released by loosening the filler plug 1 one turn 2 Wait a few minutes until the oil level is constant 3 Remove the filler plug 1 and top up with oil until the pointer of the oil level gauge 2 is in the upper part of the green area 4 Reinstall and tighten the filler plug 1 2 1 ...

Page 67: ...rain plugs 4 Catch the oil in a drain pan Unscrew the filler plug 2 to speed up draining After draining reposition and tighten the drain plugs 4 3 Remove the oil filters 1 e g by means of a special tool Catch the oil in a drain pan 4 Clean the filter seat on the manifold taking care that no dirt drops into the system Oil the gasket of the new filter element Screw it into place until the gasket con...

Page 68: ...ssor oil filter s and close the oil vessel according to the instructions 6 Fill the oil vessel with the minimum amount of replacement oil run the compressor under light load conditions for 30 minutes 7 Thoroughly drain the system when the oil is warm leaving as little oil in the system as possible especially in dead areas if possible blow out remaining oil by pressurising the oil 8 Fill the system...

Page 69: ... PARCOOL EG inhibits corrosion deposit formation is minimized This effectively eliminates flow restriction problems through the engine coolant ducts and the radiator minimizing the risk of engine overheating and possible failure It reduces water pump seal wear and has excellent stability when subjected to sustained high operating temperatures PARCOOL EG is free of nitride and amines to protect you...

Page 70: ...G COOLANT CHECK In order to guarantee the lifetime and quality of the product thus optimising engine protection regular coolant condition analysis is recommended The quality of the product can be determined by three parameters Visual check Verify the appearance of the coolant with regard to its colour and make sure that no loose particles are floating around pH measurement Check the pH value of th...

Page 71: ... 5 5 6 0 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 Example Total volume coolant Measured concentration In case of expansion tank at low level this quantity is to be filled without draining from the cooling system 1 Refractometer indication 20 C 33 2 Refractometer indication 22 C 3 Refractometer indication 25 C 4 Refractometer indication 30 C 5 Refractometer indication 36 C Liter Vol Liter PARCOOL E...

Page 72: ...otal volume coolant Measured concentration In case of expansion tank at normal level this quantity is to be drained from the cooling system 1 Refractometer indication 20 C 33 2 Refractometer indication 22 C 3 Refractometer indication 25 C 4 Refractometer indication 30 C 5 Refractometer indication 36 C Liter Vol Liter PARCOOL EG Concentrate PN 1604 8159 00 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60...

Page 73: ...ngine operation temperature is reached Turn off the engine and allow to cool Recheck coolant level and add if necessary CLEANING COOLERS Keep the coolers 1 2 and 3 clean to maintain the cooling efficiency Service doors 4 are provided on both sides of the fan cowl to allow easy access to the fan side surface of the coolers Clean by air jet in the direction of the arrow Steam cleaning in combination...

Page 74: ... check the electrolyte level in each cell if required top up with distilled water only When charging batteries each cell must be open i e plugs and or cover removed Preferably use the slow charging method and adjust the charge current according to the following rule of thumb Battery capacity in Ah divided by 20 gives safe charging current in Amp MAKE UP DISTILLED WATER The amount of water evaporat...

Page 75: ...y covered with petroleum jelly Carry out periodic condition tests Test intervals of 1 to 3 months depending on climate and operating conditions are recommended If doubtful conditions are noticed or malfunctions arise keep in mind that the cause may be in the electical system e g loose terminals voltage regulator maladjusted poor performance of compressor etc COMPRESSOR ELEMENT OVERHAUL When a comp...

Page 76: ... pressure and decreased to lower it by turning the adjusting wheel clockwise and anti clockwise respectively To adjust the normal working pressure proceed as follows 1 Loosen the lock nut of the regulating valve 2 Release Regulating Valve turn out 3 With the outlet valves 2 closed adjust the regulating valve 1 until a pressure is reached of nominal pressure 1 5 bar 22 psi 4 Lock the regulating val...

Page 77: ...idge 3 is an indication of a malfunctioning filter element 3 Reassemble in reverse order of dismantling 4 Inspect and tighten all air intake connections 1 Snap clips 4x 4 Filter element 2 Dust trap cover 5 Filter housing 3 Safety cartridge 6 Vacuator valve The Atlas Copco air filters are specially designed for the application The use of non original air filters may lead to severe damage of the eng...

Page 78: ... order to purge trapped air see paragraph Specific start procedure The fuel system should be primed under the following conditions Compressor is put in operation for the first time Running out of fuel Storage Replacement of the fuel filter Daily drain condensate 2 1 All adjustments or repairs are to be done by an authorized representative of the safety valve 2 supplier see section Specific safety ...

Page 79: ...mp 5 Close vent when fuel begins to purge 8 Check for leaks retighten if necessary Drain instructions 1 Open bowl drain valve 1 operate pump 5 and pump water out 2 Close drain valve 1 CLEANING CRANKCASE BREATHER FILTER 1 After switching off the engine let it cool down for about 30 minutes 2 Open the clasps 2 and carefully separate the bowl from the head Be aware that hose 3 is still attached 3 Tak...

Page 80: ...eel brakes Re adjust brakes if necessary As a check apply the parking brake slightly and check that the braking effect on the wheels in the direction of travel is the same on the right and on the left ABS BRAKING SYSTEM Pneumatic setting on the relay valve The pre dominance of the pneumatic braking system is pre set and is not to be changed Pre set pre dominance for compressor type 06287 06264 and...

Page 81: ...rake lever 3 several times by hand with a force of 200 to 300 N and put it back into the not engaged tooth 1 position Adjust the turnbuckle 1 as described above Testing the parking brake For testing the parking brake apply the parking brake lever Brake power must be reached between the 16th and 23rd tooth of the toothed segment Z Y 1 2 2 l 1 Z 16 23 3 Z W Y Tighten all lock nuts 2 Torque 24 Nm ...

Page 82: ...rking brake lever 3 several times by hand with a force of 200 to 300 N and put it back into the not engaged tooth 1 position Adjust the turnbuckle 1 as described above Testing the parking brake For testing the parking brake apply the parking brake lever Brake power must be reached between the 6th and 14th tooth of the toothed segment Z 3 Z Y Y 2 2 1 Z 14 6 1 Tighten all lock nuts 2 Torque 24 Nm ...

Page 83: ...e visible in the inner part of the turnbuckle Apply the parking brake lever 3 several times by hand with a force of 200 to 300 N and put it back into the not engaged tooth 1 position Adjust the turnbuckle 1 as described above Testing the parking brake For testing the parking brake apply the parking brake lever The nominal brake power must be reached between the 6th and 12th tooth of the toothed se...

Page 84: ...sible in the inner part of the turnbuckle Apply the parking brake lever 3 several times by hand with a force of 200 to 300 N and put it back into the not engaged tooth 1 position Adjust the turnbuckle 1 as described above Testing the parking brake For testing the parking brake apply the parking brake lever The nominal brake power must be reached between the 6th and 12th tooth of the toothed segmen...

Page 85: ... an Atlas Copco Service representative Blow down valve stuck in open position Check and correct as necessary Loading valve LV leaking past O ring With compressor running at max load speed disconnect hose leading to unloader If air leaks from the hose remove and inspect loading valve Replace damaged or worn O rings Oil separator element clogged Have element removed and inspected by an Atlas Copco S...

Page 86: ...ews first remove the short screws then release the spring tension unscrewing the long ones Minimum pressure valve malfunctioning Remove and inspect valve Blow off valve malfunctioning Remove and inspect valve Possible faults Corrective actions Engine oil pressure too low Refer to the engine instruction manual Compressor or engine overheating See corrective actions Compressor overheating Fuel tank ...

Page 87: ...nt compressor cooling Locate compressor away from walls when banked with other compressors leave space between them Oil cooler clogged externally Clean oil cooler Refer to section Cleaning coolers Oil cooler clogged internally Consult Atlas Copco Oil filters clogged Replace oil filters Oil level too low Check oil level Top up with recommended oil if necessary Thermostatic by pass valve remains stu...

Page 88: ...act Check electrical wiring Blocked air duct or exhaust gas duct Check combustion air duct and exhaust gas duct Glow plug defective Replace glow plug Fan motor defective Replace fan motor Possible faults Corrective actions Overheating Cool down and start again Possible faults Corrective actions Upper or lower voltage limit is reached Check power Possible faults Corrective actions Device switched o...

Page 89: ...pressor to a truck for more flexibility or to a frame when it is to be used permanently in an installation In combination with the support mounted it is also possible to integrate larger fuel tank to get larger intervals between two fuel supply actions SKID LARGE FUELTANKS The skid is ideal in circumstances where the site is impossible to reach by truck It allows transportation by crane or fork li...

Page 90: ... this additional fuel filter gives an extra protection to the fuel combustion system PREHEATER The preheater is a device for preheating the cooling fluid before starting when operating at low temperatures The engine will start more easy Additionally the preheater will lengthen the life span of the engine as there are no cold starts see also section Preheater option ...

Page 91: ... inlet shut down valve is a safety device preventing the engine from over speeding when sucking in combustible fumes When the engine max RPM is exceeded a pneumatically controlled solenoid valve closes off the air inlet and the fuel supply to the engine is cut FUELXPERT This is a control module that regulates engine speed and the air inlet to optimise fuel consumption depending on the working cond...

Page 92: ... compressor controller A warning can be set at a value between 0 C and 115 C default value and a shut down can be set at a value between 0 C and 120 C default value The operator has authority to modify these values so the process can be guarded and kept in a safe condition under all circumstances See also table Fault codes on page 53 The installation includes a by pass over the after cooler For ap...

Page 93: ...diosignal This is particularly comfortable when the compressor can not be positioned directly at the job site because of blocking by buildings or other obstacles ABS BREAKING SYSTEM Improves braking stability from higher transport speeds compliant to 98 12 EC WAGON TOW BAR LEVEL DEVICE The tow bar levelling device is an ergonomic device making it easier for the operating personnel to couple the co...

Page 94: ...re attached to the axle of the compressor ROAD SIGNALISATION On road bumper bars and lights can be specified in accordance with local legislation REHEATER PACKAGE For quality dry air a reheater can be fitted in combination with the aftercooler This allows air quality to be delivered at ambient 60 C ...

Page 95: ...ORS IN OUTLET For applications were the air outlet temperature is important additional sensors can be installed in the manifold ADDITIONAL MANIFOLD For more flexibility it is possible to have additional outlets installed ...

Page 96: ...5 144 23 M16 315 233 23 Assemblies Torque value Nm lbf ft Axles to frame Wheel nuts 270 200 10 0 Bolts front axle frame 205 152 10 Bolts rear axle frame 205 152 10 Compressor to frame Bolts elements gear casing 46 34 10 Bolts elements support 80 60 10 Bolts support buffer 205 152 10 Bolts buffer frame 80 60 10 Engine to frame Bolts engine support 205 152 10 Bolts support buffer 46 34 10 Bolts buff...

Page 97: ... 8 6 10 3 12 14 psi 125 149 174 203 Designation XAMS 527 XAMS 1150 XATS 487 XATS 1050 XAHS 447 XAHS 950 XAVS 407 XAVS 900 Minimum effective receiver pressure bar e 4 4 4 4 psi 58 58 58 58 Maximum effective receiver pressure compressor unloaded bar e 10 11 7 13 4 13 4 psi 145 170 194 194 Maximum ambient temperature at sea level without aftercooler C 50 50 50 50 F 122 122 122 122 with aftercooler C ...

Page 98: ...oler l s 510 472 433 396 cfm 1001 1000 918 840 Fuel consumption at 100 FAD Fuel expert kg h 45 0 45 2 44 8 45 1 lb h 100 7 101 1 100 3 101 0 No Fuel expert kg h 45 0 45 2 44 8 45 1 lb h 100 7 101 1 100 3 101 0 at 75 FAD Fuel expert kg h 35 1 35 5 35 3 35 7 lb h 78 7 79 4 79 1 79 8 No Fuel expert kg h 40 2 40 4 40 3 40 7 lb h 89 9 90 5 90 3 91 1 at 50 FAD Fuel expert kg h 30 3 30 7 30 7 31 1 lb h 6...

Page 99: ...3 Engine oil consumption maximum g h 112 4 113 0 112 1 112 8 oz h 3 96 3 98 3 95 3 98 Compressed air temperature at outlet valve C 90 90 90 90 F 194 194 194 194 Noise level Sound pressure level LP complies with ISO 2151 EPA under free field conditions at 7 m distance dB A 72 76 72 76 72 76 72 76 Sound power level LW complies with 2000 14 EC dB A 100 100 100 100 Sound power level LW complies with 8...

Page 100: ...4 0 ft 0 1000 2000 3000 4000 XAMS 527 XAMS 1150 125 psi 8 6 bar 14 32 50 68 86 104 122 10 0 10 20 30 40 50 ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C 3 281 6 562 9 843 13 124 0 ft 0 1000 2000 3000 4000 XATS 487 XATS 1050 150 psi 10 3 bar 14 32 50 68 86 104 122 10 0 10 20 30 40 50 ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C ...

Page 101: ...si 12 bar 14 32 50 68 86 104 122 10 0 10 20 30 40 50 ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C 3 281 6 562 9 843 13 124 0 ft 0 1000 2000 3000 4000 XAVS 407 XAVS 900 200 psi 14 bar 14 32 50 68 86 104 122 10 0 10 20 30 40 50 ALTITUDE m ALTITUDE ft TEMPERATURE F TEMPERATURE C ...

Page 102: ... Caterpillar Type C9 Tier 3 Coolant Liquid Number of cylinders 6 Bore mm 112 in 4 41 Stroke mm 149 in 5 87 Swept volume l 8 81 cu in 538 Output acc to 80 1269 EEC at normal shaft speed kW 224 hp 300 Load factor1 85 Designation All units Capacity of oil sump Initial fill l 34 US gal 9 Refill max 2 l 32 US gal 8 4 Capacity of cooling system l 54 US gal 14 3 ...

Page 103: ...approx 1 m3 s 13 1 cfm 2 7 104 Designation All units Flow rate l m 50 US gal m 13 Self priming from dry up to m 2 4 ft 7 8 Designation All units Range m 350 ft 1150 The maximum range in the open field is 350 metres with full batteries Obstacles between receiver and control unit should be avoided When using several remote controlled units please take care that there is a distance between two receiv...

Page 104: ...eye C Maximum permitted load on axle or front axle on dual axle units D Maximum permitted load on rear axle on dual axle units 8 Model 9 Working pressure 10 Speed 11 Engine power 12 Manufacturing year 13 CE mark in accordance with Machine Directive 89 392 EC 14 Register number or number of notified body Atlas Copco Airpower n v Atlas Copco Airpower n v Boomsesteenweg 957 B 2610 WILRIJK 0038 kg kg ...

Page 105: ... 18 18 psi 232 232 261 261 Design temperature C 130 130 130 130 F 266 266 266 266 Designation XAMS 527 XAMS 1150 XATS 487 XATS 1050 XAHS 447 XAHS 950 XAVS 407 XAVS 900 Standard Cold start equipment Standard Cold start equipment Design pressure bar e 18 18 18 18 psi 261 261 261 261 Design temperature max C 130 130 130 130 F 266 266 266 266 Design temperature min C 10 25 10 25 F 14 13 14 13 Volume l...

Page 106: ... 106 PARTS SUBJECTED TO CAT I AND COVERED BY THE MACHINE DIRECTIVE 89 392 EC All other parts PARTS SUBJECTED TO ART I PARAGRAPH 3 3 All other parts ...

Page 107: ...cycling in the future is forseen DISPOSAL OF MATERIALS Dispose of contaminated substances and material separately in accordance with locally applicable environmental legislation Before dismantling a machine at the end of its operating lifetime drain and dispose of all fluids of according the applicable local disposal regulations Remove the batteries Do not throw batteries into the fire explosion r...

Page 108: ... 108 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 109: ...hinery complies also with the requirements of the following directives and their amendments as indicated Directive on the approximation of laws of the Member States relating to Harmonized and or Technical Standards used Att mnt a Pressure equipment 97 23 EC X b Machinery safety 2006 42 EC EN ISO 12100 1 EN ISO 12100 2 EN 1012 1 c Simple pressure vessel 87 404 EEC X d Electromagnetic compatibility ...

Page 110: ... 110 Notes ...

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