Atlas Copco XRVS 1350, Instruction Manual

Page 1: ...XRYS 577 Cd S3B APP XRYS 1260 CD7 T4I APP XRXS 607 Cd S3B APP XRXS 1275 CD7 T4I APP XRVS 647 Cd S3B APP XRVS 1350 CD7 T4I APP Instruction Manual for Portable Compressors English Engine CAT C18 ...

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Page 3: ...OPCO PORTABLE ENERGY DIVISION www atlascopco com Printed matter N 2954 6700 00 11 2012 Instruction Manual for Portable Compressors XRYS 577 XRYS 1260 XRXS 607 XRXS 1275 XRVS 647 XRVS 1350 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 2012 Atlas Copco Airpower n v Antwerp Belgium Any unauthorized use or copying of the contents o...

Page 5: ...diagram exhaust aftertreatment 24 3 2 1 Exhaust Gas Aftertreatment all units 25 3 3 Electric system 26 3 3 1 Circuit diagram index 26 3 3 2 SH3 Engine circuit 28 3 3 3 SH4 Compressor circuit 30 3 3 4 SH5 Compressor control module 31 3 3 5 SH6 Optional equipment 32 3 3 6 SH7 Optional equipment 34 3 3 7 SH8 Optional equipment 36 3 4 Fuse box 37 3 5 Undercarriage 38 3 5 1 Wagon 38 3 5 2 Tandem EU 39 ...

Page 6: ... 15 4 Make up distilled water 96 5 15 5 Periodic battery service 97 5 16 Compressor element overhaul 97 6 Adjustments and servicing procedures 98 6 0 1 Adjustment of the continuous pneumatic regulating system 98 6 1 Air filters engine compressor 99 6 1 1 Main parts 99 6 1 2 Cleaning the dust trap 99 6 1 3 Replacing the filter element and the safety cartridge 99 6 1 4 Air receiver 100 6 1 5 Safety ...

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: ...y 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 To lift heavy parts a hoist of ample capacity tested and approved according to local s...

Page 10: ...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 engine has sufficiently cooled down 13 Never refill fuel while the unit is running unless otherwise stated in the Atlas Copco Instruction Book AIB Keep fuel aw...

Page 11: ...ached to the starting equipment On engine driven units the battery shall be disconnected and removed or the terminals covered by insulating caps On electrically driven units the main switch shall be locked in open position and the fuses shall be taken out A warning sign bearing a legend such as work in progress do not supply voltage shall be attached to the fuse box or main switch 4 Before dismant...

Page 12: ...unction 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 When hot parts have to be handled e g shrink fitting special heat resistant gloves shall be used and if required other body protection shall be applied 22 When using cartridge type breathing filter equipment ascertain that the...

Page 13: ...e 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 sa...

Page 14: ...o oil pump The oil is removed from the air in the air oil vessel first by centrifugal force secondly by the oil separator element The vessel is provided with an oil level indicator Regulation XRYS compressor The compressor is provided with a dual pressure electronic regulating system The DrillAirXpert variable regulating system gives full control of compressor pressure and flow It controls vessel ...

Page 15: ...e 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 is located at the back on the left hand side of the canopy It is equipped with a protective metal cover for safety and protection The contro...

Page 16: ...V LV LV FPco OLG RVlp RVhp PSS BF OFce OFce CU CU C C OT BS BS B B FFp FFp FFf FFf AOV TSlp PS CElp OFe EP FL F FT SN TB BH DPF IC FCc CLS FC R OC SV AR MPV E FFp AFe AFce TShp CEhp DPar DPce DPgc DPoc DPr DPeo UV ASV ...

Page 17: ...ug Radiator E Engine Reference Name EP Exhaust Pipe F Fan FC Fuel Cooler FCc Filler Cap coolant FFp Fuel Prefilter FFf Fuel Fine Filter Caterpillar FL Fuel Level FPco Filler Plug oil compressor element FT Fuel Tank IC Intercooler LV Loading Valve XRVS XRXS MPV Minimum Pressure Valve OC Oil Cooler OFce Oil Filter compressor element OFe Oil Filter engine OLG Oil Level Gauge OT Oiltronix PS Pressure ...

Page 18: ... 18 REGULATING SYSTEM OVERVIEW BVof AFe AFE SC AFS AFc DE WPS OT OFc SL TBV AR SV OSE MPV DP AOV EW C DAXc BOsv PSlp TShp OSV TSlp CU CEhp OC F E CH OFe CElp PSai DAXiv DAXsm XRYS ...

Page 19: ...et Valve DAXsm DrillAirXpert Stepper Motor DE Dust Evacuator DP Drain Plug E Engine EW Electrical Wiring F Fan MPV Minimum Pressure Valve OC Oil Cooler OFc Oil Filter compressor OFe Oil Filter engine Reference Name OSE Oil Separator Element OSV Oil Stop Valve OT Oiltronix PSai Pressure Sensor air inlet PSlp Pressure Sensor low pressure SC Safety Cartridge SL Scavenge Line SV Safety Valve SVbos Sol...

Page 20: ...mpressor element AFE Air Filter Element AFe Air Filter engine AFS Air Filter Switch AOV Air Outlet Valves AR Air Receiver BOV Blow Off Valve BVof Bypass Valve oil filter C Cubicle CEhp Compressor Element high pressure CElp Compressor Element low pressure CH Coupling Housing CU Control Unit CV Check Valve DE Dust Evacuator DP Drain Plug E Engine EW Electrical Wiring F Fan LV Loading Valve ...

Page 21: ...ure Selection Switch RV Regulating Valve RVlp Regulating Valve low pressure SC Safety Cartridge SL Scavenge Line SV Safety Valve TBV Thermostatic Bypass Valve TShp Temperature Sensor high pressure TSlp Temperature Sensor low pressure UA Unloader Assembly WPS Working Pressure Sensor AFe AFE SC AFS AFce DE BVof OFce TBV SL WPS AR SV OSE MPV RV LV DP AOV EW C OC F E UA BOV CH OFe CElp PSlp TShp OSV T...

Page 22: ...tic by pass valve starts opening when the oil temperature is 40 C 104 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 bearing housings The injected oil mixed with the compressed air leaves the compressor element and re en...

Page 23: ...s fully open If the air consumption is less than the maximum air output air receiver pressure increases and the regulating valve supplies control air to throttle valve to reduce the air output and holds air receiver pressure between the normal working pressure and the corresponding unloading pressure Unloading pressure normal working pressure 1 bar 14 504 psi When the air consumption is resumed th...

Page 24: ... 24 FLOW DIAGRAM EXHAUST AFTERTREATMENT HPFP DOC EAM DPF ...

Page 25: ...Oxidation Catalyst DOC and a filter module The DOC reduces CO HC and NO through oxidation It also produces NO2 to regenerate the DPF The filter system removes 99 of particulate matter Step 3 Active regeneration Particulate matter left in the filter system is burned in a process called regeneration Extending the lifetime of a filter it converts particulate matter into CO2 and ash Atlas Copco engine...

Page 26: ...ng alternator H10 Light Internal H11 Light Internal H4 Flasher light H6 Horn H7 Flasher light H8 Light Internal H9 Light Internal Tag Desc 1 Desc 2 Sheet Col K0 Solenoid Starter motor K1 Relay Fuel priming pump K10 Relay Remote control K11 Relay Roof actuator K12 Relay Micro PLC K13 Relay Etherstart K2 Relay Compressor P A C K3 Relay Refuel pump K4 Relay Air shut off valve K5 Relay Aftercooler fan...

Page 27: ...ature sensor Ambient temperature TT4 Temperature sensor Ambient temperature TT5 Temperature sensor Aftercooler air discharge temperature TT6 Temperature sensor Air discharge temperature Tag Desc 1 Desc 2 Sheet Col X1 Connector XC3003 4003 primary X10A Connector Air shut off valve X10B Connector Preheater X10C Connector Internal lights X10D Connector Dual pressure preset X11 Remote control Receiver...

Page 28: ... 28 SH3 ENGINE CIRCUIT 1 2 3 5 6 7 8 9 G 4 10 A B C D E F 3 A 3 B 3 D 3 C 3 E 3 G 3 H 3 I 3 F 9822 0963 68 ...

Page 29: ... 29 Reference Name 3 A Engine PAC 3 B CCM CAN Bus 3 C CAN End Resistor 3 D Compressor PAC 3 E Relay for CRS Power 3 F Diagnostic 3 G Relay for CRS Pump 3 H CAT Interconnect 12 Pole 3 I STD Engine ...

Page 30: ... 30 SH4 COMPRESSOR CIRCUIT 9822 0963 68 ...

Page 31: ... 31 SH5 COMPRESSOR CONTROL MODULE 5 A Reference Name 5 A Customer Remote Installation 9822 0963 68 ...

Page 32: ... 32 SH6 OPTIONAL EQUIPMENT 6 A 6 B 6 C 6 D 9822 0963 68 Reference Name 6 A Refuel Pump 6 B Air Discharge Sensors 6 C Air shut Off Valve 6 D Aftercooler Fans ...

Page 33: ... 33 6 E 6 F 6 G 9822 0963 68 Reference Name 6 E Blow Down Valve 6 F Aftercooler Air Discharge Sensors 6 G External Fuel Switch ...

Page 34: ... 34 SH7 OPTIONAL EQUIPMENT 7 A 7 B 9822 0963 68 Reference Name 7 A Preheater Arctic 7 B Oiltronix ...

Page 35: ... C Etherstart 7 D Remote Control 7 D Remote Control X11 3 Remote Off On 4 Remote Start 5 Remote Stop 6 Remote Load No Load 8 GND for digital inputs 10 Remote DC Power Supply X3 3 Remote Off On 8 GND for digital inputs 10 Remote DC Power Supply ...

Page 36: ... 36 SH8 OPTIONAL EQUIPMENT 8 A 8 B 8 C Reference Name 8 A Internal Lights 8 B Roof Actuator 8 C Option Box 9822 0963 68 ...

Page 37: ...reset Pressure 8 E AirXpert 9822 0963 68 Reference Name F1 Main circuit breaker F2 Engine control module F3 CAT regeneration system F4 Fuel priming pump F6 Refuel pump F8 Internal lights F9 Preheater Nordic F10 Roof actuator F13 Charging alternator ...

Page 38: ...ipped with a parking brake only It consists of drum brakes installed on the rear wheels and a lever that is connected through a steel wire linkage to the brakes The parking brake is applied by moving a lever 10 in the direction of the arrow 10 9 7 4 1 1 5 ...

Page 39: ... the undercarriage has two foldable support legs to be used when the compressor is in position for operation For easy access of the control panel a small foldable ladder is installed The compressor is to be coupled to an appropiate truck by means of a height adjustable towing device and towing eye The maximum recommended speed for safely towing the compressor is 80 km h Inappropriate use Transport...

Page 40: ...ted when the supply line from the towing vehicle is disconnected To be able to move the compressor without having to connect the brake lines pull the black button 2 until it snaps into place To activate the service brake press the button 2 Reference Name 1 Spring loaded brake Parking 2 Service brake Secure the compressor with wheel chocks If the parking brake is released the spring loaded brake is...

Page 41: ...p to the case of the spring brake Now using the wrench tighten the nut and thus compressing the spring and releasing the brake You must perform this operation on all spring brakes Deactivate the emergency release before the journey and before you put the pressure on the handbrake back Resetting the emergency release If the brake system operating pressure reaches at least 5 2 bar 75 4 psi you will ...

Page 42: ...er supply 24 V 2 5 mm2 brown blue 10 Sensor for brake lining wear indicator 1 5 mm2 brown red 11 Pressure sensor of the spring brake 1 5 mm2 yellow black 12 Lifting axle 1 5 mm2 pink 13 Ground connection for data line 2 5 mm2 white black 14 Data line 1 5 mm2 purple 15 Data line 1 5 mm2 orange Nr Function Cable cross section Line colour 1 Plus terminal solenoid valve KL 30 4 or 6 mm2 red 2 Plus ter...

Page 43: ...urs Warning 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 9 5 bar 138 psi Tyre pressure Wagon 7 5 bar 109 psi Tyre pressure Tandem EU 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...

Page 44: ...her traffic participants cannot see any braking action Other traffic participants cannot see the compressor in darkness This may result in injuries or even death Check the connections before each trip When the air pressure is not connected the compressor cannot brake This may result in injuries or even death Do not drive diagonally up a slope When driving on slopes in an extremely slanted position...

Page 45: ... itself during the trip As a result of related accidents people may get injured killed or equipment may be damaged When working on the electrics always disconnect the compressor s power supply from the truck If the power supply is not disconnected before working on the electrics you may get injured when touching the leads Do not step on the tow bar When stepping on the tow bar it may fold down due...

Page 46: ... temporarily in an out of level position not exceeding 15 If the compressor is parked on sloping ground immobilize the compressor by placing wheel chocks available as option in front of or behind the wheels TANDEM EU When removing the compressed air hoses the compressor s service brake is activated automatically Please pay attention to the sequence in which you disconnect the air lines 1 Release t...

Page 47: ...ocking pin 2 and lower the support leg as far as possible Lock the support leg with the pin and secure it with the hairpin spring 3 Only operate the parking brake when it is cold Using the parking brake when the brakes are overheated may create tension fields on account of different cooling down speeds which may cause damage to the brake discs High temperatures may result in the brake pads getting...

Page 48: ... 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 TANDEM EU Adjust the height of the towing eye if necessary Loosen the bolts 1 and 3 Adjust the height of the towing eye by turning bolt 2 After adjusting fasten bolts 1 and 3 Before towing the compressor ensure that the towing equipment of the ...

Page 49: ...people may get injured killed or equipment may be damaged Remove hairpin spring 3 and take out the pin 2 Slide the leg extension upwards as far as possible and lock it with the pin 2 Secure the pin with the hairpin spring Release the support lock 1 turn the support leg upwards and secure it in horizontal position with the support lock When driving without the ladder being completely raised the lad...

Page 50: ... brackets Release the spindle parking brake Check the following before each trip Security of the wheel chocks Plug and socket connections for electrics and compressed air Functioning of light system Functioning of brake system Has the compressor been coupled properly Have the support legs been raised Is the release valve of the service brake Button 1 pressed closed Is the parking brake released Bu...

Page 51: ...s into control interval This is followed by the fan continuing to run for about 130 sec The signal lamp will stay lit during the control interval and also the waterpump continues to run If the heater does not ignite within 90 seconds after fuel pumping has started the start procedure must be repeated If the heater once again fails to ignite after 90 seconds a fault shut down is effected It is poss...

Page 52: ...s By pressing button 1 once twice or three times you will select pre set time 1 2 or 3 The display shows e g pre set time 1 and symbol 1 Set the pre set period with buttons 2 or 3 With button 4 you can activate or deactivate the pre set period When activated the symbol ON appears and the symbol 1 2 or 3 Operation Switching ON the heater Press button 4 The heating period lasts minutes The display s...

Page 53: ... fuel filters until clean fuel flows from the drain cock 8 Empty the dust trap of each air filter AF See section Replacing the filter element and the safety cartridge 9 Clogged air filter s will be indicated on the display of the control panel see section Fault codes If indicated replace the filter elements 10 Check coolant level in engine coolant top tank integrated in radiator Top up if necessar...

Page 54: ...ted BATTERY SWITCH The compressor is equipped with a battery switch When the compressor is not in use this switch must always be in the OFF position It is not allowed to use this switch as an emergency switch or for stopping the compressor It will cause damage in the control unit when using this switch for stopping Always first shut off the control unit and wait until the display is dark before sw...

Page 55: ...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 56: ...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 57: ... text 3 Compressor info Main View Indication Measuring View Indication Settings View Indication Alarm View Indication DPF REGENERATION High Exhaust System Temperature Means that the Diesel Particle Filter is being regenerated DPF REGENERATION NEEDED Means that the Diesel Particle Filter needs to be regenerated Please force DPF Regeneration ...

Page 58: ... dedicated icon PRESET Depending of which Pressure and or Flow setting is active the controller 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 A...

Page 59: ...lected and entered to access the sublist MAIN VIEW LOADED 1300RPM 22 4bar 41 1286h 22 4 MEASUREMENTS LOADED 1300RPM 22 4bar 41 1286h Running Hours 1286h ECU Engine rpm 1300 rpm ECU Requested Speed 1300 rpm ECU DPF Soot Load 24 Vessel Pressure 22 4 bar HP Element Temperature 101 C Ambient Temperature 27 C SETTINGS LOADED 1300RPM 22 4bar 41 1286h 1000 GENERAL SETTINGS 2000 DIGITAL INPUTS 3000 VOLTAG...

Page 60: ...pening 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 down for as long as the vessel pressure is higher than 1 5...

Page 61: ...l 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 MAIN VIEW PREPARING FOR START 0 0 RPM 0 0bar 41 1286h MAIN VIEW READING ENGINE DATA 0 0 RPM 0 0bar 41 1286h Active Buttons Stop Button to cancel Start command Load Button to activate ...

Page 62: ...ay 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 800RPM 324RPM 0RPM MAIN VIEW ENGINE CRANKING 324RPM 0 0bar 41 1286h Active Buttons Stop Button to cancel Start command Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button 120s 54s 0s MA...

Page 63: ...mand Load Button to activate Automatic Load Measurement View Button Settings View Button Alarms View Button MAIN VIEW ENGINE WARMING UP 1200RPM 2 9 bar 41 1286h 15s 7s 0s Active Buttons Stop Button to cancel Start command Load Button to initiate Automatic Load Measurement View Button Settings View Button Alarms View Button MAIN VIEW READY TO LOAD 4 6 1200RPM 4 6bar 41 1286h ...

Page 64: ...f 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 MAIN VIEW BUILDING UP VESSEL PRESSURE 3 9 1200RPM 3 9bar 41 1286h Active Buttons Stop Button to cancel Start command Load Button to cancel Load command Mea...

Page 65: ...rticulate filter is above 30 when a stop command is given the controller will ask the user if it is allowed to perform a complete DPF Regeneration cycle before stopping When ENTER is pressed the HEST icon will appear See paragraph DIESEL PARTICULATE FILTER REGENERATION The doors must be closed during operation and may be opened for short periods for inspection and adjustments only Be aware not to ...

Page 66: ...in the OFF position It is not allowed to use this switch as an emergency switch or for stopping the compressor It can damage the controller or the engine s Electronic Control Unit when using the battery switch for stopping Always first shut off the controller and wait until the display is dark before switching the battery switch to position OFF Active Buttons Start Button to initiate Start command...

Page 67: ... Soot Load LSR Low Speed Regeneration This can happen in following situations Warming Up Not Loaded Loaded when running in Unload condition minimum RPM Cooldown When an LSR is ongoing while the soot load is less than 60 and the engine speed changes engine is stopped machine gets loaded then the DPF Regeneration process will be stopped If the Soot Load is higher than 30 when cooling down should sta...

Page 68: ...will show the DPF Regeneration Needed Icon In case of Inhibited DPF Regeneration the DPF Regeneration Needed Icon will overwrite the DPF Inhibited Icon Required Action Force DPF Regeneration see paragraph FORCE DPF REGENERATION When DPF Regeneration is started the DPF Regeneration Needed icon will disappear and the HEST icon will pop up SOOT LOAD reaches 90 only when DPF Regeneration is Inhibited ...

Page 69: ...nowledge the ECU DPF SOOT LOAD HIGH warning press Enter while in the Main View Force DPF Regeneration see paragraph FORCE DPF REGENERATION When DPF Regeneration is started the DPF Regeneration Needed icon will disappear and the HEST icon will pop up SOOT LOAD reaches 101 If still no action is taken the following warning appears and the controller will perform a controlled shutdown As soon as the e...

Page 70: ...enu Scroll one line down and Enter the 1140 ECU DPF REGENERATION menu OR Scroll down and Enter the MODE parameter Scroll down and Enter the AUTOMATIC setting Press the Back button 3 times to get back to the Main View DPF Regeneration setting will now be AUTOMATIC DPF REGENERATION Customer Level can now select between AUTO Regeneration INHIBIT Regeneration as long as the controller is not powered d...

Page 71: ... to the preferred month and press ENTER To change any other RTC setting the red figure is editable Scroll up down and press ENTER to change Use left right to shift between editable figures Now press BACK until you re back in the Main View or in the menu you require Set Language Press the SETTINGS VIEW button scroll to 1000 GENERAL SETTINGS press ENTER scroll to 1300 LANGUAGES ENTER the LANGUAGES m...

Page 72: ...ngine diagnostics Now press BACK until you re back in the Main View or in the menu you require To leave Diagnostics press the STOP button Set the Pressure Flow Setpoint only on AirXpert machines When the controller is in the Main View shift between PRESSURE and FLOW VIEW with right left arrows Press ENTER for 2 seconds and the middle section becomes green setting can be edited Press the UP DOWN ar...

Page 73: ...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 ΔP 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 74: ...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 75: ...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 76: ...ell as by the software When the emergency stop button 1 is pressed the operator can unlock the emergency stop by turning it counterclockwise Always use the remote control function in accordance to local work area legislation 1 Start Engine 2 Stop Engine 3 Load unload compressor The emergency stop button is only to be used in emergency situations not for stopping procedures 1 ...

Page 77: ... 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 unload...

Page 78: ...enance 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 pak XRYS 577 XRYS 1260 2912 4559 05 2912 4560 06 XRXS 607 XRXS 1275 2912 4559 05 2912 4567 06 XRVS 647 XRVS 1350 2912 4559 05 2912 4559 06 For the most important subassemblies Atlas Cop...

Page 79: ...rque 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 Obtain engine oil sample 2 12 x x Drain Clean fuel tank water and sediments 1 x x x Replace fan belt x x x Hoses and clamps Inspect Replace x x x Change engine oil 2 x x x x Re...

Page 80: ...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 Replace air filter element 1 x x x Check external fuel connection option x x x Inspection by Atlas Copco service technician x x x Adjust engi...

Page 81: ...alve 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 flexibles every 6...

Page 82: ...ing 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 dama...

Page 83: ... year Related instructions can be found in the following subsections In principle damaged parts have to be repaired or replaced Any other inspection jobs have to be carried out regularly by an expert at 6 month intervals Inspection list for the expert 1 To be performed by skill level 2 Mechanical technician 2 To be performed by skill level 3 Electrical technician Inspection jobs After the first ev...

Page 84: ...tection 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 Stage IIIB 3 2 TIER 4 Interim 3 2 engines running on low sulphur diesel for lower oil and fuel consumption PAROIL E xtra is a Synthetic ultra high performance diesel engine oil with a hig...

Page 85: ... F 22 F 32 F 14 F 4 F PAROIL S xtreme PAROIL S xtreme PAROIL S PAROIL S Synthetic compressor oil PAROIL S Mineral 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 container 1000 264 1630 0182 00 ...

Page 86: ...86 F 68 F 50 F 40 F 22 F 32 F 14 F 4 F PAROIL E xtra PAROIL E MISSION GREEN PAROIL E xtra PAROIL E MISSION GREEN Synthetic engine oil PAROIL E xtra Mineral engine oil PAROIL E Mission Green 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 1630 0471 00 can 20 5 3 1630 0472 00 barrel 210 55 2 1630 0473 00 ...

Page 87: ...n the upper extremity of the green range Add oil if necessary DIESEL FUEL RECOMMENDATIONS Before removing the oil filler plug 2 ensure that the pressure is released by opening an air outlet valve 3 3 1 2 Ultra Low Sulfur Diesel ULSD fuel 0 0015 percent 15 ppm mg kg sulfur is required by regulation for use in engines certified by regulation for use in engines certified to nonroad Tier 4 standards U...

Page 88: ...il drain intervals more frequent oil drain intervals Increase overall operating costs Failures that result from the use of improper fuels will not be covered by warranty OIL AND OIL FILTER CHANGE ENGINE OIL AND OIL FILTER CHANGE See section Preventive maintenance schedule TOPPING UP THE COMPRESSOR OIL 1 Stop the compressor Wait a few minutes until the pressure is released through the automatic blo...

Page 89: ...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 90: ...in a new oil separator screw on new compressor 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...

Page 91: ... 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 92: ...OOLANT 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 the c...

Page 93: ... 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 94: ...al 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 6...

Page 95: ...l normal engine 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 c...

Page 96: ...ys 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 evapor...

Page 97: ...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 98: ...ual pressure system option for XRXS The dual pressure system has two regulating valves marked with RVlp and RVhp and a switch at the rear for selecting the lower RVlp or higher RVhp working pressure Set the regulating valve marked with RVlp at a working pressure lower than the regulating valve marked with RVhp This means the handle of RVlp should be scewed in less than the handle of RVhp This pres...

Page 99: ...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 100: ...the lifting gear twice a year This can be done by screwing the cap of the valve anti clockwise An annual check of the set pressure according to local regulations This check cannot be done on the compressor and must be carried out on a proper test bench 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 Spe...

Page 101: ... engine continues to misfire or smoke repeat Step 1 Manual switch priming if equipped The manual switch is located on the primary filter base electric priming pump assembly 1 Hold the manual switch in the up position until fuel has filled the water separator 2 Continue to hold the switch for 30 seconds after the water separator is full 3 Attempt to start the engine If engine starts and runs rough ...

Page 102: ...t 2 Close drain valve 1 BRAKE SYSTEM ADJUSTMENT Brake shoe adjustment Wagon Tighten the adjustment nut 1 on the wheel brake with a spanner until the wheel will not rotate in the direction of travel Centre the brake shoes by applying the parking brake several times Turn back the adjustment bolt 1 by approximately one turn until no braking effect can be felt when the wheel is turned in a forward dir...

Page 103: ...ke lever 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 8 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 10 Z 9 7 Y Y 11 11 8 Z 14 6 1 Tighten all lock nuts 11 Torque 24 Nm ...

Page 104: ...th a clean cloth For lubrication purposes use commercial vehicle grease Lubricate the tow bar using a grease gun on the lubrication nipples Lubrication point of folding supports Prior to lubrication please clean the lubrication nipple 1 with a clean cloth For lubrication purposes use commercial vehicle grease Lubricate the folding supports using a grease gun on the lubrication nipple Inspections a...

Page 105: ...ario block the brakes To stop the brake system from freezing in winter we recommend you use an anti freeze agent You have to drain all the compressor s brake system compressed air tanks The drainage valves can be found in the middle underneath the tanks Pull the activation bolt of the drainage valve to the side Hold the bolt until no more condensation water is coming out Release the activation bol...

Page 106: ...y 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 ...

Page 107: ...rews 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 108: ...ent 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 st...

Page 109: ...ompressed air system Visit a garage One brake drum is defective Visit a garage Possible faults Corrective actions The compressed air system is leaking and operating pressure is not achieved Visit a garage Feed line pressure is too low Connect the compressor to a truck Possible faults Corrective actions Feed line pressure is too low Connect the compressor to a truck One brake drum is defective Visi...

Page 110: ...ons Cables or hoses are becoming detached Drive to the nearest authorised service centre The stand has not been raised and is becoming detached Fold up the stand and have it properly fixed again in an authorised service centre The spindle parking brake is still activated Release the spindle parking brake Possible faults Corrective actions The towing eye s bearing is stuck Lubricate the towing eye ...

Page 111: ...Heater shuts off Problem Control unit locked Possible faults Corrective actions No fuel Check fuel level Fuse blown Check fuse Bad electrical contact 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...

Page 112: ...iminates the need for having a second truck to transport the compressor leading to a lower investment cost in the operation and faster job turnover Highest reliability Extra large fuel tanks are provided as standard The maximum speed is 90 km hr 56 mph Towing eyes options DIN or NATO SUPPORT MOUNTED LARGE FUELTANKS With the option Support mounted it is possible to fix the compressor to a truck for...

Page 113: ...o the exact location In combination with the skid it is also possible to integrate larger fuel tank to get larger intervals between two fuel supply actions WHEEL CHOCKS For extra safe parking on slopes ADDITIONAL FUELFILTER In dusty environments or in situations where the fuel quality is not up to the normal standard this additional fuel filter gives an extra protection to the fuel combustion syst...

Page 114: ...he tank from which is being refueled is empty 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 COLD WEATHER PACKAGE The cold start option consists of larger batteries and a blow off valve to be able t...

Page 115: ...FUEL CONNECTION When a compressor is operated on site for a longer period it is advisable to supply the fuel through external fuel connections When using this option the regular refuelling by tanker it is no more needed Consequently there is also less risk for contamination when refuelling INTERNAL LIGHTING The internal lighting circuit is equipped with a timer When the internal lighting is switch...

Page 116: ...working conditions and the output required This option contains one regulating valve REGULATING SYSTEM DUAL PRESSURE NO FUEL EXPERT With this option it is possible to set the pressure to two particular pressures REGULATING SYSTEM DUAL PRESSURE FUEL EXPERT This option combines the dual pressure regulating system with the fuel optimising system thus saving on fuel costs ...

Page 117: ... hand held pneumatic tools PRESSURE REGULATOR ASME A pressure regulating system according to US standards for reducing the operating pressure It will limit the operating pressure to 7 bar and allow the operation of hand held pneumatic tools FORK LIFT SLOTS With fork lift slots the compressor can easily be moved with a fork lift truck on building sites where it is impossible to use a towing truck ...

Page 118: ...s so the process can be guarded and kept in a safe condition under all circumstances See also table Fault codes on page 73 The installation includes a by pass over the after cooler For applications that demand quality air a fine filtration unit 2 can be specified with the after cooler package This will remove oil and particles down to 0 01 mg m3 For purer but not breathing air an active charcoal f...

Page 119: ... 24 M12 120 89 25 M14 195 144 23 M16 315 233 23 Assemblies Torque value Nm lbf ft Axles to frame Wheel nuts 270 200 Bolts front axle frame 205 152 Bolts rear axle frame 205 152 Compressor to frame Bolts elements gear casing 46 34 Bolts elements support 80 60 Bolts support buffer 205 152 Bolts buffer frame 80 60 Engine to frame Bolts engine support 205 152 Bolts support buffer 46 34 Bolts buffer fr...

Page 120: ...ng pressure bar e 35 30 25 psi 508 435 363 Designation XRYS 577 XRYS 1260 XRXS 607 XRXS 1275 XRVS 647 XRVS 1350 Minimum effective receiver pressure bar e 22 19 16 psi 319 276 232 Maximum effective receiver pressure compressor unloaded bar e 35 32 27 psi 507 464 392 Maximum ambient temperature at sea level without aftercooler C 48 48 48 F 118 118 118 with aftercooler C 45 45 45 F 113 113 113 Minimu...

Page 121: ...g r min 1625 Engine shaft speed compressor unloaded r min 1300 1300 1200 Free air delivery 1 at 22 bar 320 psi pressure setting without aftercooler l s 676 cfm 1433 with aftercooler l s 658 cfm 1395 Free air delivery 1 at 25 bar 363 psi pressure setting without aftercooler l s 648 648 cfm 1374 1374 with aftercooler l s 629 629 cfm 1333 1333 Free air delivery 1 at 30 bar 435 psi pressure setting wi...

Page 122: ...25 bar 363 psi pressure setting kg h 57 1 53 3 lb h 125 9 117 5 at 30 bar 435 psi pressure setting kg h 59 8 lb h 131 9 at 35 bar 508 psi pressure setting kg h 56 6 lb h 125 at 25 FAD at 25 bar 363 psi pressure setting kg h 46 4 42 0 lb h 102 3 92 6 at 30 bar 435 psi pressure setting kg h 50 5 lb h 111 4 at 35 bar 508 psi pressure setting kg h 45 8 lb h 101 at unload at 25 bar 363 psi pressure set...

Page 123: ... 0 003 Compressed air temperature at outlet valve without aftercooler C 102 102 102 F 216 216 216 Air volume at inlet grating approx 3 m3 s 15 1 14 6 16 3 cu ft s 530 513 573 Noise level Sound pressure level LP at 7 m distance dB A 80 78 80 Sound power level LW is measured according to ISO 3744 dB A 108 106 108 Designation XRYS 577 XRYS 1260 XRXS 607 XRXS 1275 XRVS 647 XRVS 1350 1 Free air deliver...

Page 124: ...contact XRYS 577 XRYS 1260 10 0 10 20 30 40 50 14 34 54 74 94 114 0 1000 2000 2500 3000 1500 500 0 1000 2000 3000 4000 5000 6000 7000 9000 8000 35 bar 508 psi Altitude m Altitude ft Temperature F Temperature C XRXS 607 XRXS 1275 10 0 10 20 30 40 50 14 34 54 74 94 114 0 1000 2000 2500 3000 1500 500 0 1000 2000 3000 4000 5000 6000 7000 9000 8000 30 bar 435 psi Altitude m Altitude ft Temperature F Te...

Page 125: ...25 XRVS 647 XRVS 1350 10 0 10 20 30 40 50 14 34 54 74 94 114 0 1000 2000 2500 3000 1500 500 0 1000 2000 3000 4000 5000 6000 7000 9000 8000 25 bar 363 psi Altitude m Altitude ft Temperature F Temperature C ...

Page 126: ... Liquid Liquid Liquid Number of cylinders 6 6 6 Bore mm 145 145 145 in 5 71 5 71 5 71 Stroke mm 183 183 183 in 7 2 7 2 7 2 Swept volume l 18 1 18 1 18 1 cu in 1104 5 1104 5 1104 5 Maximum power output according to SAE J1995 kW 447 447 447 hp 599 599 599 Engine Rating IND B IND B IND B Designation All units Capacity of oil sump Initial fill l 64 US gal 16 9 Refill max 1 l 62 US gal 16 4 Capacity of...

Page 127: ...r l 143 US gal 37 8 Capacity of fuel tank wagon l 975 US gal 258 Capacity of fuel tank tandem l 750 US gal 198 Capacity of fuel tank option large fuel tank tandem skid support mounted l 1520 US gal 409 Designation All units Range m 200 ft 656 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 Wagon bar e 8 5 psi 123 Tandem EU Type 235 ...

Page 128: ... EYE 6612 DIN TOWING EYE 6614 2520 4568 2246 2276 2251 4562 5 2435 2705 2251 3046 6829 9822 0831 51 C18 T4A Wagon 9822 0831 53 C18 T4A Skid mounted 9822 0831 52 C18 T4A Support mounted 9822 0831 54 C18 T4A EU Tandem Weight maximum see indication on dataplate ...

Page 129: ...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 130: ... 40 35 30 psi 580 508 435 Design temperature C 130 130 130 F 266 266 266 Designation XRYS 577 XRYS 1260 Standard Cold Start Equipment XRXS 607 XRXS 1275 Standard Cold Start Equipment XRVS 647 XRVS 1350 Standard Cold Start Equipment Design pressure bar e 40 35 35 psi 580 508 508 Design temperature max C 130 130 130 F 266 266 266 Design temperature min C 25 25 25 F 13 13 13 Volume l 143 143 143 US g...

Page 131: ... 131 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 132: ...ycling in the future is foreseen 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 133: ... 133 Maintenance Log Compressor Customer Serial number Service hours Maintenance action Date By initials ...

Page 134: ...irements of this directive The machinery 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 x C E 3 2 7 9 t n e m p i u q e e r u s s e r P b Machinery safety 2006 42 EC EN ISO 12100 1 EN ISO 12100 2 EN 1012 1 d Electromagnetic ...

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