2954 2880 02_xr(v,x,y)s 557-647_en
TRANSCRIPT
XRYS 557 Cd - XRYS 1220 CD7XRXS 567 Cd - XRXS 1240 CD7XRXS 607 Cd - XRXS 1275 CD7 Engine CAT C18XRVS 617 Cd - XRVS 1300 CD7XRVS 647 Cd - XRVS 1350 CD7
Instruction Manualfor Portable CompressorsEnglish
ATLAS COPCO - PORTABLE AIR DIVISIONwww.atlascopco.com
Original instructions
Printed matter N°2954 2880 02
01/2010
Instruction Manualfor Portable Compressors
XRYS 557 Cd - XRYS 1220 CD7XRXS 567 Cd - XRXS 1240 CD7XRXS 607 Cd - XRXS 1275 CD7XRVS 617 Cd - XRVS 1300 CD7XRVS 647 Cd - XRVS 1350 CD7
Warranty and Liability LimitationUse only authorized parts.Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or ProductLiability.The manufacturer does not accept any liability for any damage arising for modifications, additions orconversions made without the manufacturer's approval in writing.While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does notassume responsibility for possible errors.
Copyright 2009, Atlas Copco Airpower n.v., Antwerp, Belgium.Any unauthorized use or copying of the contents or any part thereof is prohibited.This applies in particular to trademarks, model denominations, part numbers and drawings.
Neglecting maintenance or making changes to the setup of the machine can result in majorhazards, including fire risk.
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PrefacePlease read the following instructions carefullybefore starting to use your compressor.It is a solid, safe and reliable machine, builtaccording to the latest technology. Follow theinstructions in this booklet and we guarantee youyears of troublefree operation.Always keep the manual available near the machine.In all correspondence always mention thecompressor type and serial number, shown on thedata plate.The company reserves the right to make changeswithout prior notice.
Table of contents1 Safety precautions ...................................... 71.1 Introduction .................................................. 71.2 General safety precautions ........................... 81.3 Safety during transport and installation ....... 91.4 Safety during use and operation................... 91.5 Safety during maintenance and repair........ 111.6 Tool applications safety ............................. 121.7 Specific safety precautions......................... 13
2 Leading particulars .................................. 142.1 General description .................................... 14
3 Main parts ................................................. 163.1 Regulating system ...................................... 183.1.1 Overview................................................ 183.1.2 Air flow.................................................. 193.1.3 Oil system .............................................. 193.1.4 Pneumatic regulating system ................. 203.2 Electric system ........................................... 223.3 Markings and information labels ............... 24
4 Operating instructions ............................. 254.1 Parking, towing and lifting instructions ..... 254.1.1 Parking instructions Wagon................... 254.1.2 Towing instructions Wagon................... 264.1.3 Towbar levelling Wagon........................ 264.1.4 Lifting instructions................................. 264.2 Internal lighting.......................................... 274.3 Preheater (option)....................................... 274.3.1 Description heating operation ................ 274.4 Before starting ............................................ 29
4.5 Starting / Stopping ..................................... 304.5.1 Control panel ......................................... 304.5.2 Operations overview.............................. 314.5.3 Battery switch ........................................ 314.5.4 Specific start procedure ......................... 324.5.5 Power ON / OFF.................................... 334.5.6 Starting................................................... 334.5.7 Warming up ........................................... 344.5.8 Loading .................................................. 344.5.9 Fault codes ............................................. 354.5.10 Stopping................................................. 374.5.11 Starting / Stopping via remote control... 374.5.12 Emergency stop ..................................... 384.5.13 Info......................................................... 384.5.14 Options................................................... 394.5.15 Electric refuel pump (option)................. 404.5.16 Service task confirmed .......................... 404.5.17 Service in advance ................................. 40
5 Maintenance ............................................. 415.1 Liability...................................................... 415.2 Service paks ............................................... 415.3 Service kits................................................. 415.3.1 Storage ................................................... 415.3.2 Safety precautions.................................. 415.4 Preventive maintenance schedule
for the compressor...................................... 425.5 Oil specifications........................................ 455.5.1 Compressor oil....................................... 455.5.2 Engine oil............................................... 465.6 Oil level check ........................................... 475.6.1 Check engine oil level ........................... 475.6.2 Check compressor oil level.................... 475.7 Oil and oil filter change ............................. 48
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5.7.1 Engine oil and oil filter change .............. 485.7.2 Topping up the compressor oil............... 485.7.3 Compressor oil and oil filter change ...... 485.8 Coolant specifications ................................ 495.8.1 PARCOOL EG....................................... 505.8.2 Handling PARCOOL EG....................... 515.9 Coolant check ............................................. 515.10 Topping up/replacing coolant..................... 515.10.1 Topping up without draining
from the cooling system......................... 525.10.2 Topping up after limited quantity
draining from the cooling system........... 535.10.3 Replacing the coolant............................. 545.11 Cleaning coolers ......................................... 545.12 Battery care................................................. 555.12.1 Electrolyte .............................................. 555.12.2 Activating a dry-charged battery............ 555.12.3 Recharging a battery .............................. 555.12.4 Battery maintenance............................... 555.13 Compressor element overhaul .................... 55
6 Adjustments and servicing procedures .. 566.0.1 Adjustment of the pneumatic
regulating system ................................... 566.1 Air filters engine / compressor ................... 576.1.1 Main parts .............................................. 576.1.2 Cleaning the dust trap ............................ 576.1.3 Replacing the filter element and
the safety cartridge ................................. 576.1.4 Air receiver............................................. 586.1.5 Safety valve............................................ 586.2 Fuel system................................................. 586.2.1 Priming instructions ............................... 586.2.2 Replacing filter elements........................ 59
6.2.3 Cleaning crankcase breather filter ......... 596.2.4 Maintenance Quick action
fuel couplings......................................... 606.3 Brake adjustments ...................................... 606.3.1 Brake shoe adjustment Wagon............... 606.3.2 Brake adjustment wagon........................ 61
7 Problem solving ........................................ 627.1 Heater failure.............................................. 657.2 Oiltronix failure.......................................... 65
8 Available options ...................................... 66
9 Technical specifications ........................... 749.1 Torque values ............................................. 749.1.1 General torque values ............................ 749.1.2 Critical torque values ............................. 749.2 Compressor / engine specifications............ 759.2.1 Reference conditions.............................. 759.2.2 Limitations ............................................. 759.2.3 Performance data ................................... 769.2.4 Altitude unit performance curve ............ 789.2.5 Design data............................................. 79
10 Dataplate ................................................... 82
11 Legislation ................................................. 8311.1 Parts, subjected to Pressure Equipment
Directive 97/23/EC, cat. II and above........ 8311.2 Parts, subjected to cat. I and covered
by the Machine Directive 89/392/EC......... 8411.3 Parts, subjected to art. I, paragraph 3.3 ...... 84
12 Disposal ..................................................... 8512.1 General ....................................................... 8512.2 Disposal of materials.................................. 85
13 Maintenance Log...................................... 86
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Safety precautions
INTRODUCTION
The policy of Atlas Copco is to provide the users oftheir equipment with safe, reliable and efficientproducts. Factors taken into account are amongothers:- the intended and predictable future use of the
products, and the environments in which they areexpected to operate,
- applicable rules, codes and regulations,- the expected useful product life, assuming proper
service and maintenance,- providing the manual with up-to-date
information.Before handling any product, take time to read therelevant instruction manual. Besides giving detailedoperating instructions, it also gives specificinformation about safety, preventive maintenance,etc.Keep the manual always at the unit location, easyaccessible to the operating personnel.See also the safety precautions of the engine andpossible other equipment, which are separately sentalong or are mentioned on the equipment or parts ofthe unit.These safety precautions are general and somestatements will therefore not always apply to aparticular unit.Only people that have the right skills should beallowed to operate, adjust, perform maintenance orrepair on Atlas Copco equipment.
It is the responsibility of management to appointoperators with the appropriate training and skill foreach category of job.Skill level 1: OperatorAn operator is trained in all aspects of operating theunit with the push-buttons, and is trained to know thesafety aspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unitthe same as the operator. In addition, the mechanicaltechnician is also trained to perform maintenance andrepair, as described in the instruction manual, and isallowed to change settings of the control and safetysystem. A mechanical technician does not work onlive electrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the samequalifications as both the operator and the mechanicaltechnician. In addition, the electrical technician maycarry out electrical repairs within the variousenclosures of the unit. This includes work on liveelectrical components.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer orits agent to perform complex repairs or modificationsto the equipment.In general it is recommended that not more than twopeople operate the unit, more operators could lead tounsafe operating conditions.
Take necessary steps to keep unauthorized personsaway from the unit and eliminate all possible sourcesof danger at the unit.When handling, operating, overhauling and/orperforming maintenance or repair on Atlas Copcoequipment, the mechanics are expected to use safeengineering practices and to observe all relevant localsafety requirements and ordinances. The followinglist is a reminder of special safety directives andprecautions mainly applicable to Atlas Copcoequipment.These safety precautions apply to machineryprocessing or consuming air. Processing of any othergas requires additional safety precautions typical tothe application and are not included herein.Neglecting the safety precautions may endangerpeople as well as environment and machinery:- endanger people due to electrical, mechanical or
chemical influences,- endanger the environment due to leakage of oil,
solvents or other substances,- endanger the machinery due to function failures.All responsibility for any damage or injury resultingfrom neglecting these precautions or by non-observance of ordinary caution and due care requiredin handling, operating, maintenance or repair, also ifnot expressly mentioned in this instruction manual, isdisclaimed by Atlas Copco.
To be read attentively and acted accordingly before towing, lifting, operating, performingmaintenance or repairing the compressor.
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The manufacturer does not accept any liability for anydamage arising from the use of non-original parts andfor modifications, additions or conversions madewithout the manufacturer’s approval in writing.If any statement in this manual does not comply withlocal legislation, the stricter of the two shall beapplied.Statements in these safety precautions should not beinterpreted as suggestions, recommendations orinducements that it should be used in violation of anyapplicable laws or regulations.
GENERAL SAFETY PRECAUTIONS
1 The owner is responsible for maintaining the unitin a safe operating condition. Unit parts andaccessories must be replaced if missing orunsuitable for safe operation.
2 The supervisor, or the responsible person, shall atall times make sure that all instructions regardingmachinery and equipment operation andmaintenance are strictly followed and that themachines with all accessories and safety devices,as well as the consuming devices, are in goodrepair, free of abnormal wear or abuse, and arenot tampered with.
3 Whenever there is an indication or any suspicionthat an internal part of a machine is overheated,the machine shall be stopped but no inspectioncovers shall be opened before sufficient coolingtime has elapsed; this to avoid the risk ofspontaneous ignition of oil vapour when air isadmitted.
4 Normal ratings (pressures, temperatures, speeds,etc.) shall be durably marked.
5 Operate the unit only for the intended purpose andwithin its rated limits (pressure, temperature,speeds, etc.).
6 The machinery and equipment shall be kept clean,i.e. as free as possible from oil, dust or otherdeposits.
7 To prevent an increase in working temperature,inspect and clean heat transfer surfaces (coolerfins, intercoolers, water jackets, etc.) regularly.See the Preventive maintenance schedule forthe compressor.
8 All regulating and safety devices shall bemaintained with due care to ensure that theyfunction properly. They may not be put out ofaction.
9 Care shall be taken to avoid damage to safetyvalves and other pressure-relief devices,especially to avoid plugging by paint, oil coke ordirt accumulation, which could interfere with thefunctioning of the device.
10 Pressure and temperature gauges shall be checkedregularly with regard to their accuracy. They shallbe replaced whenever outside acceptabletolerances.
11 Safety devices shall be tested as described in themaintenance schedule of the instruction manualto determine that they are in good operatingcondition. See the Preventive maintenanceschedule for the compressor.
12 Mind the markings and information labels on theunit.
13 In the event the safety labels are damaged ordestroyed, they must be replaced to ensureoperator safety.
14 Keep the work area neet. Lack of order willincrease the risk of accidents.
15 When working on the unit, wear safety clothing.Depending on the kind of activities these are:safety glasses, ear protection, safety helmet(including visor), safety gloves, protectiveclothing, safety shoes. Do not wear the hair longand loose (protect long hair with a hairnet), orwear loose clothing or jewelry.
16 Take precautions against fire. Handle fuel, oil andanti-freeze with care because they areinflammable substances. Do not smoke orapproach with naked flame when handling suchsubstances. Keep a fire-extinguisher in thevicinity.
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SAFETY DURING TRANSPORT AND INSTALLATION
Transport of the unit has to be done by authorized/experienced people.When towing, lifting or transporting the compressorin any way, the battery switch must always be in the“OFF” position!To lift a unit, all loose or pivoting parts, e.g. doors andtow bar, shall first be securely fastened.Do not attach cables, chains or ropes directly to thelifting eye; apply a crane hook or lifting shacklemeeting local safety regulations. Never allow sharpbends in lifting cables, chains or ropes.Helicopter lifting is not allowed.It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas. Lifting acceleration and retardationshall be kept within safe limits.1 Before towing the unit:
- ascertain that the pressure vessel(s) is (are)depressurized,
- check the tow bar, the brake system and thetowing eye. Also check the coupling of thetowing vehicle,
- check the towing and brake capability of thetowing vehicle,
- check that the tow bar, jockey wheel or standleg is safely locked in the raised position,
- ascertain that the towing eye can swivel freelyon the hook,
- check that the wheels are secure and that thetyres are in good condition and inflatedcorrectly,
- connect the signalisation cable, check all lightsand connect the pneumatic brake couplers,
- attach the safety break-away cable or safetychain to the towing vehicle,
- remove wheel chocks, if applied, anddisengage the parking brake,
- check wether springs on wheelchocks aremissing or broken.
2 To tow a unit use a towing vehicle of amplecapacity. Refer to the documentation of thetowing vehicle.
3 If the unit is to be backed up by the towingvehicle, disengage the overrun brake mechanism(if it is not an automatic mechanism).
4 Never exceed the maximum towing speed of theunit (mind the local regulations).
5 Place the unit on level ground and apply theparking brake before disconnecting the unit fromthe towing vehicle. Unclip the safety break-awaycable or safety chain. If the unit has no parkingbrake or jockey wheel, immobilize the unit byplacing chocks in front of and/or behind thewheels. When the tow bar can be positionedvertically, the locking device must be applied andkept in good order. The unit must always be used/parked/stored in a non publicly accessible area,locked away from access by unauthorizedpersons.
6 To lift heavy parts, a hoist of ample capacity,tested and approved according to local safetyregulations, shall be used.
7 Lifting hooks, eyes, shackles, etc., shall never bebent and shall only have stress in line with theirdesign load axis. The capacity of a lifting devicediminishes when the lifting force is applied at anangle to its load axis.
8 For maximum safety and efficiency of the liftingapparatus all lifting members shall be applied asnear to perpendicular as possible. If required, a
lifting beam shall be applied between hoist andload.
9 Never leave a load hanging on a hoist.10 A hoist has to be installed in such a way that the
object will be lifted perpendicular. If that is notpossible, the necessary precautions must be takento prevent load-swinging, e.g. by using twohoists, each at approximately the same angle notexceeding 30° from the vertical.
11 Locate the unit away from walls. Take allprecautions to ensure that hot air exhausted fromthe engine and driven machine cooling systemscannot be recirculated. If such hot air is taken inby the engine or driven machine cooling fan, thismay cause overheating of the unit; if taken in forcombustion, the engine power will be reduced.
12 Before moving the compressor, switch it off.13 If the warning light on the ABS module or in the
vehicle lights up, please contact Atlas Copco.
SAFETY DURING USE AND OPERATION
1 When the unit has to operate in a fire-hazardousenvironment, each engine exhaust has to beprovided with a spark arrestor to trap incendiarysparks.
2 The exhaust contains carbon monoxide which is alethal gas. When the unit is used in a confinedspace, conduct the engine exhaust to the outsideatmosphere by a pipe of sufficient diameter; dothis in such a way that no extra back pressure iscreated for the engine. If necessary, install anextractor. Observe any existing local regulations.Make sure that the unit has sufficient air intakefor operation. If necessary, install extra air intakeducts.
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3 When operating in a dust-laden atmosphere, placethe unit so that dust is not carried towards it by thewind. Operation in clean surroundingsconsiderably extends the intervals for cleaningthe air intake filters and the cores of the coolers.
4 Close the compressor air outlet valve beforeconnecting or disconnecting a hose. Ascertainthat a hose is fully depressurized beforedisconnecting it. Before blowing compressed airthrough a hose or air line, ensure that the open endis held securely, so that it cannot whip and causeinjury.
5 The air line end connected to the outlet valvemust be safeguarded with a safety cable, attachednext to the valve.
6 No external force may be exerted on the air outletvalves, e.g. by pulling on hoses or by installingauxiliary equipment directly to a valve, e.g. awater separator, a lubricator, etc. Do not step onthe air outlet valves.
7 Never move a unit when external lines or hosesare connected to the outlet valves, to avoiddamage to valves, manifold and hoses.
8 Do not use compressed air from any type ofcompressor, without taking extra measures, forbreathing purposes as this may result in injury ordeath. For breathing air quality, the compressedair must be adequately purified according to locallegislation and standards. Breathing air mustalways be supplied at stable, suitable pressure.
9 Distribution pipework and air hoses must be ofcorrect diameter and suitable for the workingpressure. Never use frayed, damaged ordeteriorated hoses. Replace hoses and flexiblesbefore the lifetime expires. Use only the correcttype and size of hose end fittings and connections.
10 If the compressor is to be used for sand-blastingor will be connected to a common compressed-airsystem, fit an appropriate non-return valve (checkvalve) between compressor outlet and theconnected sand-blasting or compressed-airsystem. Observe the right mounting position/direction.
11 Before removing the oil filler plug, ensure that thepressure is released by opening an air outletvalve.
12 Never remove a filler cap of the cooling watersystem of a hot engine. Wait until the engine hassufficiently cooled down.
13 Never refill fuel while the unit is running, unlessotherwise stated in the Atlas Copco InstructionBook (AIB). Keep fuel away from hot parts suchas air outlet pipes or the engine exhaust. Do notsmoke when fuelling. When fuelling from anautomatic pump, an earthing cable should beconnected to the unit to discharge staticelectricity. Never spill nor leave oil, fuel, coolantor cleansing agent in or around the unit.
14 All doors shall be shut during operation so as notto disturb the cooling air flow inside thebodywork and/or render the silencing lesseffective. A door should be kept open for a shortperiod only e.g. for inspection or adjustment.
15 Periodically carry out maintenance worksaccording to the maintenance schedule.
16 Stationary housing guards are provided on allrotating or reciprocating parts not otherwiseprotected and which may be hazardous topersonnel. Machinery shall never be put intooperation, when such guards have been removed,before the guards are securely reinstalled.
17 Noise, even at reasonable levels, can causeirritation and disturbance which, over a longperiod of time, may cause severe injuries to thenervous system of human beings. When the soundpressure level, at any point where personnelnormally has to attend, is:- below 70 dB(A): no action needs to be taken,- above 70 dB(A): noise-protective devices
should be provided for people continuouslybeing present in the room,
- below 85 dB(A): no action needs to be takenfor occasional visitors staying a limited timeonly,
- above 85 dB(A): room to be classified as anoise-hazardous area and an obvious warningshall be placed permanently at each entranceto alert people entering the room, for evenrelatively short times, about the need to wearear protectors,
- above 95 dB(A): the warning(s) at theentrance(s) shall be completed with therecommendation that also occasional visitorsshall wear ear protectors,
- above 105 dB(A): special ear protectors thatare adequate for this noise level and thespectral composition of the noise shall beprovided and a special warning to that effectshall be placed at each entrance.
18 The unit has parts, which may be accidentallytouched by personnel, of which the temperaturecan be in exess of 80 °C (176 °F). The insulationor safety guard, protecting these parts shall not beremoved before the parts have cooled down toroom temperature.
19 Never operate the unit in surroundings wherethere is a possibility of taking in flammable ortoxic fumes.
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20 If the working process produces fumes, dust orvibration hazards, etc., take the necessary steps toeliminate the risk of personnel injury.
21 When using compressed air or inert gas to cleandown equipment, do so with caution and use theappropriate protection, at least safety glasses, forthe operator as well as for any bystander. Do notapply compressed air or inert gas to your skin ordirect an air or gas stream at people. Never use itto clean dirt from your clothes.
22 When washing parts in or with a cleaning solvent,provide the required ventilation and useappropriate protection such as a breathing filter,safety glasses, rubber apron and gloves, etc.
23 Safety shoes should be compulsory in anyworkshop and if there is a risk, however small, offalling objects, wearing of a safety helmet shouldbe included.
24 If there is a risk of inhaling hazardous gases,fumes or dust, the respiratory organs must beprotected and depending on the nature of thehazard, so must the eyes and skin.
25 Remember that where there is visible dust, thefiner, invisible particles will almost certainly bepresent too; but the fact that no dust can be seenis not a reliable indication that dangerous,invisible dust is not present in the air.
26 Never operate the unit at pressures or speedsbelow or in excess of its limits as indicated in thetechnical specifications.
SAFETY DURING MAINTENANCE AND REPAIR
Maintenance, overhaul and repair work shall only becarried out by adequately trained personnel; ifrequired, under supervision of someone qualified forthe job.1 Use only the correct tools for maintenance and
repair work, and only tools which are in goodcondition.
2 Parts shall only be replaced by genuine AtlasCopco replacement parts.
3 All maintenance work, other than routineattention, shall only be undertaken when the unitis stopped. Steps shall be taken to preventinadvertent starting. In addition, a warning signbearing a legend such as ”work in progress; donot start” shall be attached to the startingequipment. On engine-driven units the batteryshall be disconnected and removed or theterminals covered by insulating caps. Onelectrically driven units the main switch shall belocked in open position and the fuses shall betaken out. A warning sign bearing a legend suchas ”work in progress; do not supply voltage” shallbe attached to the fuse box or main switch.
4 Before dismantling any pressurized component,the compressor or equipment shall be effectivelyisolated from all sources of pressure and the entiresystem shall be relieved of pressure. Do not relyon non-return valves (check valves) to isolatepressure systems. In addition, a warning signbearing a legend such as ”work in progress; donot open” shall be attached to each of the outletvalves.
5 Prior to stripping an engine or other machine orundertaking major overhaul on it, prevent allmovable parts from rolling over or moving.
6 Make sure that no tools, loose parts or rags are leftin or on the machine. Never leave rags or looseclothing near the engine air intake.
7 Never use flammable solvents for cleaning (fire-risk).
8 Take safety precautions against toxic vapours ofcleaning liquids.
9 Never use machine parts as a climbing aid.10 Observe scrupulous cleanliness during
maintenance and repair. Keep away dirt, coverthe parts and exposed openings with a clean cloth,paper or tape.
11 Never weld on or perform any operationinvolving heat near the fuel or oil systems. Fueland oil tanks must be completely purged, e.g. bysteam-cleaning, before carrying out suchoperations. Never weld on, or in any way modify,pressure vessels. Disconnect the alternator cablesduring arc welding on the unit.
12 Support the tow bar and the axle(s) securely ifworking underneath the unit or when removing awheel. Do not rely on jacks.
13 Do not remove any of, or tamper with, the sound-damping material. Keep the material free of dirtand liquids such as fuel, oil and cleansing agents.If any sound-damping material is damaged,replace it to prevent the sound pressure level fromincreasing.
14 Use only lubricating oils and greasesrecommended or approved by Atlas Copco or themachine manufacturer. Ascertain that theselected lubricants comply with all applicablesafety regulations, especially with regard toexplosion or fire-risk and the possibility ofdecomposition or generation of hazardous gases.Never mix synthetic with mineral oil.
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15 Protect the engine, alternator, air intake filter,electrical and regulating components, etc., toprevent moisture ingress, e.g. when steam-cleaning.
16 When performing any operation involving heat,flames or sparks on a machine, the surroundingcomponents shall first be screened with non-flammable material.
17 Never use a light source with open flame forinspecting the interior of a machine.
18 Disconnect –battery-clamp before startingelectrical servicing or welding (evt. turn battery-switch in “off” position).
19 When repair has been completed, the machineshall be barred over at least one revolution forreciprocating machines, several revolutions forrotary ones to ensure that there is no mechanicalinterference within the machine or driver. Checkthe direction of rotation of electric motors whenstarting up the machine initially and after anyalteration to the electrical connection(s) or switchgear, to check that the oil pump and the fanfunction properly.
20 Maintenance and repair work should be recordedin an operator’s logbook for all machinery.Frequency and nature of repairs can reveal unsafeconditions.
21 When hot parts have to be handled, e.g. shrinkfitting, special heat-resistant gloves shall be usedand, if required, other body protection shall beapplied.
22 When using cartridge type breathing filterequipment, ascertain that the correct type ofcartridge is used and that its useful service life isnot surpassed.
23 Make sure that oil, solvents and other substanceslikely to pollute the environment are properlydisposed of.
24 Before clearing the unit for use after maintenanceor overhaul, check that operating pressures,temperatures and speeds are correct and that thecontrol and shutdown devices function correctly.
TOOL APPLICATIONS SAFETY
Apply the proper tool for each job. With theknowledge of correct tool use and knowing thelimitations of tools, along with some common sense,many accidents can be prevented.Special service tools are available for specific jobsand should be used when recommended. The use ofthese tools will save time and prevent damage toparts.
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SPECIFIC SAFETY PRECAUTIONS
BatteriesWhen servicing batteries, always wear protectingclothing and glasses.1 The electrolyte in batteries is a sulphuric acid
solution which is fatal if it hits your eyes, andwhich can cause burns if it contacts your skin.Therefore, be careful when handling batteries,e.g. when checking the charge condition.
2 Install a sign prohibiting fire, open flame andsmoking at the post where batteries are beingcharged.
3 When batteries are being charged, an explosivegas mixture forms in the cells and might escapethrough the vent holes in the plugs. Thus anexplosive atmosphere may form around thebattery if ventilation is poor, and can remain inand around the battery for several hours after ithas been charged. Therefore:- never smoke near batteries being, or having
recently been, charged,- never break live circuits at battery terminals,
because a spark usually occurs.4 When connecting an auxiliary battery (AB) in
parallel to the unit battery (CB) with boostercables: connect the + pole of AB to the + pole ofCB, then connect the - pole of CB to the mass ofthe unit. Disconnect in the reverse order.
Pressure vesselsMaintenance/installation requirements:1 The vessel can be used as pressure vessel or as
separator and is designed to hold compressed airfor the following application:- pressure vessel for compressor,- medium AIR/OIL,- and operates as detailed on the data plate of the
vessel:- the maximum working pressure ps in bar (psi),- the maximum working temperature Tmax in
°C (°F),- the minimum working temperature Tmin in °C
(°F),- the capacity of the vessel V in l (US gal, Imp
gal, cu.ft).2 The pressure vessel is only to be used for the
applications as specified above and in accordancewith the technical specifications. Safety reasonsprohibit any other applications.
3 National legislation requirements with respect tore-inspection must be complied with.
4 No welding or heat treatment of any kind ispermitted to those vessel walls which are exposedto pressure.
5 The vessel is provided and may only be used withthe required safety equipment such asmanometer, overpressure control devices, safetyvalve, etc.
6 Draining of condensate shall be performed dailywhen vessel is in use.
7 Installation, design and connections should not bechanged.
8 Bolts of cover and flanges may not be used forextra fixation.
9 (Pressure) vessel maintenance is to be performedby Atlas Copco.
Safety valvesOperating & MaintenanceOnly trained and technically competent personnelshould consider overhaul, re-set or performancetesting of safety valves.The safety valve is supplied with either a lead securityseal or crimped cover to deter unauthorised access tothe pressure regulation device.Under no circumstances should the set pressure of thesafety valve be altered to a different pressure than thatstamped on the valve without the permission of theinstallation designer.If the set pressure must be altered then use onlycorrect parts supplied by Seetru and in accordancewith the instructions available for the valve type.Safety valves must be frequently tested and regularlymaintained.The set pressure should be periodically checked foraccuracy.When fitted, the lifting device should be operated atpressures not less than 75% of the set pressure toensure free and easy movement of internal parts.The frequency of tests is influenced by factors such asthe severity of the operating environment andaggressiveness of the pressurised medium.Soft seals and springs should be replaced as part of themaintenance procedure.Do not paint or coat the installed safety valve (see alsoPreventive maintenance schedule for thecompressor).
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Leading particularsGENERAL DESCRIPTION
The XRYS 557 Cd - XRYS 1220 CD7 is a silenced,two-stage, oil-injected screw compressor, built for anominal effective working pressure of 35 bar (510psi).The XRXS 567 Cd - XRXS 1240 CD7 and XRXS 607Cd - XRXS 1275 CD7 are silenced, two-stage, oil-injected screw compressors, built for a nominaleffective working pressure of 30 bar (435 psi).The XRVS 617 Cd - XRVS 1300 CD7 and XRVS 647Cd - XRVS 1350 CD7 are silenced, two-stage, oil-injected screw compressors, built for a nominaleffective working pressure of 25 bar (365 psi).
EngineThe compressors are driven by a 6 cilinder in-lineliquid-cooled diesel engine.The engine’s power is transmitted to the compressorelement through a heavy-duty coupling.
CompressorThe compressor casing houses two screw-type rotors,mounted on ball and roller bearings. The male rotor,driven by the engine, drives the female rotor. Thecompressor delivers pulsation-free air.Injected oil is used for sealing, cooling andlubricating purposes.The XRXS and XRVS type compressors can beequipped with two different gears, resulting indifferent FAD (Free Air Delivery).
Compressor oil systemThe oil is boosted by air pressure. The system has nooil pump.The oil is removed from the air, in the air/oil vessel atfirst by centrifugal force, secondly through the oilseparator element.The vessel is provided with an oil level indicator.
RegulationThe compressor is provided with a single or dualpressure pneumatic regulating system and a blow-offvalve which is integrated in the unloader assembly.The valve is closed during operation by air receiverpressure and opens by air receiver pressure via thecompressor element when the compressor is stopped.When the air consumption increases, the air receiverpressure will decrease and vice versa.This receiver pressure variation is sensed by theregulating valve which, by means of control air to theunloader and an electronic engine speed regulator,matches the air output to the air consumption. The airreceiver pressure is maintained between the pre-selected working pressure and the correspondingunloading pressure.
- 14 -
Cooling systemThe engine is provided with a liquid-cooler andintercooler and the compressor is provided with an oilcooler. (For available options see chapter Availableoptions.)The cooling air is generated by a fan, driven by theengine.
Safety devicesA thermal shut-down sensor protects the compressoragainst overheating. The air receiver is provided witha safety valve.The engine is equipped with low oil pressure and highcoolant temperature shut-down sensors.The electric system is equipped with a 24V mainswitch.
Frame and axlesThe compressor/engine unit is supported by rubberbuffers in a spillage-free frame.The standard compressor has a towbar with parkingbrakes.
BodyworkThe bodywork has openings for the intake and outletof cooling air and hinged doors for maintenance andservice operations. The bodywork is internally linedwith sound-absorbing material.
Lifting beamA lifting beam is accessible when a small door at thetop is opened.
Serial number
The serial number is stamped in at the front of thecompressor on the upper edge of the frame behind theright door. It is also mentioned on the data plate andinside the control box.
Control panelThe control panel grouping the air pressure gauge,control switch etc., is placed at the left hand/ rear endcorner.
Data plateThe compressor is furnished with a data plateshowing the product code, the unit serial number andthe working pressure (see chapter Dataplate).
- 15 -
Main parts
(AFe)
(CEhp)(CElp)
(FCeo)
(FFc)
(ES)
(OC) (CT)
(FCc)(EP) (CLS)
(R)(IC)
(BH)
(SN)
(F)
(AFS)
(FT)
(OFe)
(E)
(TB)
(FFpc)
(ETS)
(FCft)(FLS)
(CU)
(DPce)(DPar)(DPeo)
(DPosv)(DPce)(DPr)
(DPoc)
(AOV)(IPS)
(MPV)
(CP)(FLG)
(AFce)(SV)
(B)
(AR)
(FL)
(OLG)
(FPco)
(RPS)
(LV)(RV)
(BS)
(OFce)
(OT)
- 16 -
Reference NameAFce Air Filter (compressor element)AFe Air Filter (engine)AFS Air Filter SwitchAOV Air Outlet ValvesAR Air ReceiverATS Ambient Temperature SensorB BatteryBH Brake HandleBS Battery SwitchCElp Compressor Element (low pressure)CEhp Compressor Element (high pressure)CLS Coolant Level SwitchCP Control PanelCT Coolant TankCU Control UnitDPar Drain Plug Air ReceiverDPce Drain Plug Compressor ElementDPeo Drain Plug Engine OilDPoc Drain Plug Oil CoolerDPosv Drain Plug Oil Stop ValveDPr Drain Plug RadiatorE EngineEP Exhaust Pipe
Reference NameES Emergency StopETS Element Temperature SensorF FanFCeo Filler Cap (engine oil)FCft Filler Cap (fuel tank)FCc Filler Cap (coolant)FFpc Fuel Prefilter CaterpillarFFc Fuel Filter CaterpillarFL Flash LightFLG Fuel Level GaugeFLS Fuel Level SensorFPco Filler Plug (oil compressor element)FT Fuel TankIC IntercoolerIPS Interstage Pressure SensorLV Loading ValveMPV Minimum Pressure ValveOC Oil CoolerOFce Oil Filter (compressor element)OFe Oil Filter (engine)OLG Oil Level GaugeOT OiltronixR Radiator
Reference NameRPS Regulating Pressure SensorRV Regulating ValveSN Serial NumberSV Safety ValveTB TowbarWPS Working Pressure Sensor
- 17 -
REGULATING SYSTEM
OVERVIEW
(CU)
(AFce)
(SC)
(AFe)(AFS)
(OC)
(F)
(VV)
(SV)
(SL)
(WPS)
(AR)
(WPG)
(MPV)
(RV)
(LV)
(DP)
(AOV)
(CEhp)
(CElp)
(OSV)
(CBE)
(BOV)
(DP)(CV)
(PS)(TS)
(C)
(SV)
(E)
(TV)(UA)
(RPS)
(DP)(OT)
(TBV)
(BVof)(OFce)(FR)
Reference NameAFce Air Filter (compr. element)AFe Air Filter (engine)AFS Air Filter SwitchAOV Air Outlet ValvesAR Air ReceiverBOV Blow Off ValveBVof Bypass Valve oil filterC CouplingCBE Cubicle for Electrical devicesCElp Compressor Element (low pressure)CEhp Compressor Element (high pressure)CU Control UnitCV Check ValveDP Drain PlugE EngineF FanFR Flow RestrictorLV Loading ValveMPV Minimum Pressure ValveOC Oil CoolerOFce Oil Filter (compressor element)OSV Oil Stop ValveOT OiltronixPS Pressure Sensor
- 18 -
AIR FLOW
Air drawn through the airfilter (AFce) into thecompressor element (CElp CEhp) is compressed. Atthe element outlet, compressed air and oil pass intothe air receiver/oil separator (AR/OS).The check valve (CV) prevents blow-back ofcompressed air when the compressor is stopped. Inthe air receiver/oil separator (AR/OS), most of the oilis removed from the air/oil mixture.The oil collects in the receiver and on the bottom ofthe separator element.The air leaves the receiver via a minimum pressurevalve (MPV) which prevents the receiver pressurefrom dropping below the minimum working pressure,even when the air outlet valves are open (specified insection Limitations). This ensures adequate oilinjection and prevents oil consumption. Theminimum pressure valve (MPV) also functions as acheck valve.The system comprises temperature sensors (TS),pressure sensors (PS) and a working pressure sensor(WPS).
OIL SYSTEM
The lower part of the air receiver (AR) serves as oiltank.Air pressure forces the oil from the air receiver/oilseparator (AR/OS) through the oil cooler (OC), the oilfilters (OF) and the oil stop valve (OSV) to thecompressor element (CElp CEhp).
When the compressor is stopped and / or there is nopressure in the system, the oil stop valve (OSV)prevents the oil from flowing back into thecompressor element.The thermostatic by-pass valve (TBV) starts openingwhen the oil temperature is 80°C (176°F) (when noOiltronix is installed). With installed Oiltronix, thethermostatic by-pass valve starts opening when the oiltemperature is 40°C (104°F).The compressor element has an oil gallery in thebottom of its casing. The oil for rotor lubrication,cooling and sealing is injected through holes in thegallery.Lubrication of the bearings is ensured by oil injectedinto the bearing housings.The injected oil, mixed with the compressed air,leaves the compressor element and re-enters the airreceiver, where it is separated from the air asdescribed in section Air flow. The oil that collects inthe bottom of the oil separator element is returned tothe system through a scavenging line (SL), which isprovided with a flow restrictor (FR).The oil filter by-pass valve opens when the pressuredrop over the filter is above normal because of aclogged filter. The oil then by-passes the filterwithout being filtered. For this reason, the oil filtermust be replaced at regular intervals (see sectionPreventive maintenance schedule for thecompressor).
Reference NameRPS Regulating Pressure SensorRV Regulating ValveSC Safety CartridgeSL Scavenge LineSV Safety ValveTBV Thermostatic Bypass ValveTS Temperature SensorTV Throttle ValveUA Unloader AssemblyVV Vacuator ValveWPG Working Pressure GaugeWPS Working Pressure Sensor
- 19 -
PNEUMATIC REGULATING SYSTEM
(AR)
(RV)
(CEhp)
(CElp)
(BOV)
(TV)(UA)
- 20 -
The compressor is provided with a pneumaticregulating system and a blow-off valve (BOV) whichis integrated in the unloader assembly (UA). Thevalve is closed during operation by outlet pressure ofthe compressor element and opens by air receiverpressure when the compressor is stopped.When the air consumption increases, the air receiverpressure will decrease and vice versa. This receiverpressure variation is sensed by the regulating valve(RV) which, by means of control air to the unloaderassembly (UA), matches the air output to the airconsumption. The air receiver pressure is maintainedbetween the pre-selected working pressure and thecorresponding unloading pressure.When starting the compressor, the throttle valve (TV)is kept closed via receiver pressure. The compressorelement (CElp CEhp) takes in air and pressure buildsup in the receiver (AR). The throttle valve (TV) isclosed. The air output is controlled from maximumoutput (100%) to no output (0%) by:1. Speed control of the engine between maximum
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 themaximum air output, the engine speed is held atmaximum load speed and the throttle valve (TV) isfully open.
If the air consumption is less than the maximum airoutput, air receiver pressure increases and theregulating valve supplies control air to throttle valve(TV) to reduce the air output and holds air receiverpressure between the normal working pressure andthe corresponding unloading pressure. Unloadingpressure = normal working pressure + 1 bar (14.504psi).When the air consumption is resumed, the blow offvalve (BOV) closes and the throttle valve (TV)gradually opens the air intake and the electronic speedregulator increases the engine speed.The construction of the regulating valve (RV) is suchthat any increase (decrease) of the air receiverpressure above the pre-set valve opening pressureresults in a proportional increase (decrease) of thecontrol pressure to the throttle valve and theelectronic speed regulator.Part of the control air is vented to atmosphere, andany condensate discharged, through the vent holes.
- 21 -
ELECTRIC SYSTEM
19
85
86K5
47
4747
288
8
9999
N7 N6
18
NA1NA2NA3NA4
COM4COM3COM2COM1NA1NA2NA3NA4
ALIM
GND
RECEIVER7213465
CONTROLLERremoteconnector
19
24M
24M
24M
5SIG
BV
519
S4
24M
PH-19
X1
PH-19
PH-3
R1
PH-2
P2 PH-3
PH-19
P
PH-2
PH-4PH-1
S1
PH-24M
24M
24M
1
3
2N5
TIMER
2
34
71
N4
HYDRONIC
15AF3
PH-24
MPH
-24
Y4
X1
24M
COM
19
Y3
REF
30
87
COM
K4
SIG19 85
86K4 BV19
Y2
P146
30
87
24
K3
4619
P
308787a
K2
19
282021183536
AB
GFCE DC2
3635
M2
42 41
M
1943
15A
F2
4324
40383940
+
-
M2M1
FAB
N3END STOP
1919
19
S2
15A
F1
T-IN 01V-IN 04
C1
H-OUT 07
H-OUT 10
L-OUT 03L-OUT 02L-OUT 01
T-IN 05
D-IN 05
D-IN 06V-IN 07
C4
B14
B15
C14
A13A12A11B10
B5
C3C2
D1
A9C7
N1B1
D13D12D11
A16
CONT
ROLL
ER27
M
27M
24
J1/P1-10
J1/P1-70
J1/P1-9J1/P1-8
J1/P1-65J1/P1-63J1/P1-61
J1/P1-52N2
J1/P1-42J1/P1-34J1/P1-50
J1/P1-48
ECM
24M
K1
24VDC
19
181821212020
28
19
19
19
19U
24M
24M
24M
24
24
24
24
S1
W+
G3B+B-
D+
K0M1
MK0G2 -
+G1 -
+
1 2
3
4
8
9
10
11
F4
15A
IL-19
IL-2
IL-19
IL-19
IL-4
H7 H8 H9 H10
IL-3
IL-24
MIL-
24
19
IL-19
K6K7
2021
C AB
18
To oiltronixa8a7a6
R2
IL-24
M
IL-24
M
IL-24
M
S5
X1
(9822 0867 04 - C18 HP)
- 22 -
C1 Spare I/O (female contacts)C2 CAT engine service tool connectorF1 Fuse 15AF2 Fuse 15A, roofF3 Fuse 15A, preheaterF4 Fuse 15A, internal lightsG1 BatteryG2 BatteryG3 AlternatorH4 Warning flasher lightH6 HornH7-H10 Internal lightsK0 Relay, Starter motorK1 Relay, Aux. starter K2 Relay, Roof actuatorK3 Relay, Refuelling pumpK4 Relay, Refinary equipmentK5 Relay, Ether startK6 Timer relayK7 RelayLS1 Level Switch, Coolant level WarningLS2 Level Switch, Coolant level ShutdownLT1 Level sensor, Fuel levelM1 Starter motorM2 Roof actuatorN1 Compressor Control ModuleN2 Engine Control Module (Caterpillar)N3 Roof actuator controllerN4 Hydronic heaterN5 TimerN6 Receiver wireless remote controlN7 Compressor control module remote connectorP1 Refuelling pumpP2 Fuel pump preheaterPS1 Pressure Switch, AirfilterPT1 Pressure sensor, Vessel pressurePT2 Pressure sensor, Regulating PressurePT3 Pressure sensor, Interstage pressure
PT4 Pressure sensor, AftercoolerR1 Resistor 470 Ohm 3WR2 Termination resistor 120 OhmS1 Emergency StopS2 Battery switchS3 Fuel supply selector switchS4 Dual pressure selector switchS5 Internal lights switchTT1 Temperature sensor, PT1000, LP Element
temperatureTT2 Temperature sensor, PT1000, HP element
temperatureTT3 Temperature sensor, PT1000, Ambient
temperatureTT4 Temperature sensor, PT1000, Aftercooler Y1 Loading ValveY2 Blow-off valveY3 Air shut-off valveY4 Dual pressure valveX1 Optional equipment
1 Fused 24 VDC for Spare I/O’s and options2 24 VDC (power supply box) for Spare I/O’s and
options3 Fused 24 VDC for Spare I/O’s and options4 Fused 24 VDC after Emergency Stop for Spare
I/O’s and options5 5 VDC for Spare I/O’s and options6 Power After Contact for Spare I/O’s and options7 Digital Ground for Spare I/O’s and options8 Switched Ground for Spare I/O’s and options9 Unswitched Ground10 Switched Ground (power supply box) for Spare
I/O’s and options11 Switched Ground for Spare I/O’s and options
X1
C1
18
18
ADS-T
ADS-P
28
29
TT4T-IN 06
PT4V-
SIG
V+ 5VDCV+ 24VDC
U
P
X1
119 85
86
K1
4519 85
86
K3
19
19
2831
3428
LS1LS2
44
4419 85
86
K2
19 19
37
3719
S3
15 15 LT1SIGV-
V+ 5VDCV+ 24VDC
U
L2829
18
PT3SIGV-
V+ 5VDCV+ 24VDC
U
P
PT2SIGV-
V+ 5VDCV+ 24VDC
U
P
PT1
2829
18
2829
18
2829
3233
3332
H6H4
C10
B6
C15
A15
B4
C6
D15D16
B9
B7
D9C9
A7
B16
A3
A4
C16
A1
D7B8
C8
B3
19302
2
31
34
30
19
P
PS1Y1
1
11109
6 6
11
18
TT3
4
55
109
418
291818
V-IN 06
24M
SIGV-
V+ 5VDCV+ 24VDC
U
P
TT2TT1
56
7
CONT
ROLL
ER
- 23 -
MARKINGS AND INFORMATION LABELS
Dangerous outlet gases.
Danger, hot surface.
Electrocution hazard.
Atlas Copco synthetic compressor oil.
Atlas Copco mineral engine oil.
Manual.
Read the instruction manual before working on the battery.
Reset fuse.
On / off button.
Prohibition to open air valves without connected hoses.
Rotation direction.
Inlet.
Outlet.
Compressor oil drain.
Read the instruction manual before starting.
Service every 24 hours.
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.
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.
Read the instruction manual before topping up with coolant.
Service point.
Circuit breaker.
Do not run the compressor when the baffles are not in the right position.
- 24 -
Operating instructionsPARKING, TOWING AND LIFTING INSTRUCTIONS
Safety precautions
Attention
Uncouple vehicle.Apply parking brake by moving the lever (1) in thedirection of the arrow.Connect the safety chain (2) to the eyes (3) on thetowbar (4). You can move the towbar (4) upwards andsecure it by connecting the chain (5) to the eye (6).Place the compressor as level as possible; however, itcan be operated temporarily in an out-of-levelposition not exceeding 15°. If the compressor isparked on sloping ground, immobilize the compressorby placing wheel chocks (available as option) in frontof or behind the wheels.
Locate the rear-end of the compressor upwind, awayfrom contaminated wind-streams and walls. Avoidrecirculation of exhaust air from the engine. This cancause overheating and engine power decrease.
The operator is expected to apply allrelevant Safety precautions.
Before putting the compressor in to use,check the brake system as described insection Brake adjustments.After the first 100 km travel:Check and retighten the wheel nuts andtowbar bolts to the specified torque. Seesection Torque values.Check the brake adjustment. See sectionBrake adjustments.
When towing, lifting or transporting thecompressor in any way, the batteryswitch must always be in the “OFF”position!Also switch off the preheater as this unitis directly connected to the batteries.
PARKING INSTRUCTIONS WAGON
(5)(6)
(1)
(4)
(3)
(2)
- 25 -
TOWING INSTRUCTIONS WAGON
1. Attach the compressor to the towing vehicle.2. Move hand brake lever (1) in the direction of the
arrow till stop and connect the breakaway chain (2) to the towing vehicle.
Never move the compressor with air hoses connectedto the air outlet valves.
TOWBAR LEVELLING WAGON
The towbar of the wagon is equipped with anadjustable 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.
LIFTING INSTRUCTIONS
To lift the compressor, use a lift truck or crane withsufficient capacity (weight: see indication onDataplate).See to it that the compressor will be lifted verticallyand remains level.
Before towing the compressor, ensurethat the towing equipment of the vehiclematches the towing eye. The height ofthe towing device of the vehicle must be815 - 845 mm (31.8 - 33 in).
Before moving the compressor, switch itoff.
(1)
(2)
+
-
(1)
(2)
Lifting acceleration and retardationmust be kept within safe limits (max.2xg).Helicopter lifting is not allowed.Lifting is not allowed when the unit isrunning.
- 26 -
INTERNAL LIGHTING
The internal lighting circuit is equipped with a timer.When the internal lighting is switched on with switch(4), the timer is started. After a preset time the internallight will be switched off automatically.The timer is set by choosing a range with button (2)(default: 1 h) and setting a factor with button (1)(default: 0,2). This results in a lighting time of 12minutes.
PREHEATER (OPTION)
DESCRIPTION HEATING OPERATION
When switched on the signal lamp in the mini-clockcontrol element is lit. The waterpump starts and aftera fixed programme with prerinsing and preheating,combustion air fan, glow plug and fuel dosing pumpset combustion going. Once a stable flame hasformed, the glow plug is switched off by a timer.Depending on the heat requirement, the heater wilswitch between three levels, LARGE, SMALL andOFF (control interval). The temperature thresholdshave been fixed programmed in the electronic controldevice. If the heat requirement at level SMALL is solow that the cooling water temperature reaches 85°C(185°F), the device goes into control interval. This isfollowed by the fan continuing to run for about 130sec. The signal lamp will stay lit during the controlinterval and also the waterpump continues to run.If the heater does not ignite within 90 seconds afterfuel pumping has started, the start procedure must berepeated. If the heater once again fails to ignite after90 seconds a fault shut down is effected.It is possible to override a fault shut-down by brieflyswitching the heater off and then on again.
When an emergency stop has to be performed:• Switch off the preheater at the control element• Remove the fuse or disconnect the heater from the
battery
Safety procedure before starting after alonger period of standstill• Check whether the fuse is in its place and / or the
wiring is connected to the battery.• Check if all parts are firmly fixed.• Check the fuel system visualy on leaks.
Preheater altitude capability• Up to 1,500 meters:
no restrictions• Above 1,500 meters:
Operation possible for short periodsContinuous operation NOT possible
Do not change the setting of button (3).
(1)
(2)
(3)
(4)
Before performing any maintenancejobs always switch off the preheater andremove the fuse or disconnect the heaterfrom the battery.
Do not repeat this more than twice insuccesion!
- 27 -
General• When no button is pressed the display will return
to its default mode - normal time display.• When setting the time, holding the buttons (2) or
(3) pressed, the time will change more rapidly.• With this mini-clock you can set and activate three
pre-set times. Each pre-set time is deactivated after the set heating period has ended. It has to be activated again for each new heating action.
SettingsCommisioning• 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) longer then 3 sec.; time blinks.
Set with buttons (2) or (3). Briefly press button (1); time is displayed, colon blinks.
Setting heating period• Press button (1) longer then 3 sec.; time blinks.
Wait till the display indicates "setting heating period"; heating symbol and time blink. Set heating period (10 to 120 min) using button (2) or (3). Press button (1); time is displayed, colon blinks.
Setting pre-settings• 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".
OperationSwitching ON the heater• Press button (4). The heating period lasts
..minutes. The display shows: remaining heating time and symbol 7.
Switching OFF the heater• Press button (4). The heater will run idle for about
3 minutes. The display shows: actual time.Continuous operation• Press and hold button (3), then press button (4);
now the heater will be operating till button (4) (heater off) is pressed.
Activating/ deactivating pre-set time• Select pre-set time 1, 2 or 3 by pressing button (1).• Activate the selected time by pressing button (4).• The display shows: symbol "ON" as well as the
selected pre-set time, "1, 2 or 3".
Reference Name1 Button Mode2 Button Time down3 Button Time up4 Button ON/OFF select pre-set time5 Time, pre-set time and heating time6 Symbol pre-set time is active7 Symbol heating ON8 Symbol pre-set time 1,2 or 3
(5)
(6)(7)
(4)
(8)
(3)
(1)
(2)
If you do not press the button within 5seconds the mode is changed to “settingheating period”.
- 28 -
BEFORE STARTING
1. Before initial start-up, prepare battery for operation if not already done. See section Recharging a battery.
2. Check that the draining caps in the spillage-free frame are firmly tightened.
3. With the compressor standing level, check the level of the engine oil. Add oil, if necessary, to the upper mark on 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 oil comes out and reinstall the drain plug. The interval between draining operations may be determined by experience, as the amount of condensate depends on the operating condition.
5. Check the level of the compressor oil. See section Check compressor oil level. The pointer of oil level gauge (OLG) should register in the green range. Add oil if necessary. See section Compressor oil for the oil to be used.
6. Check that the fuel tank contains sufficient fuel. Top up, if necessary. Consult the Engine Operation Manual for the type of fuel.
7. Drain any water and sediment from the 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 necessary. Consult the Engine Operation Manual for coolant specifications.
11. Attach the air line(s) to the closed air outlet valve(s).
12. Use hoses with suitable pressure rating and fit for the environmental conditions. Always install the pull relief (2), see figure. Inspect hoses and connections daily.
13. Select fuel supply mode.
• Internal supply. Move the lever of the fuel selection supply valve upwards.
• External supply. Connect the supply and return hose to the fuel nipples at the fuel funnel. Move the lever of the fuel selection supply valve downwards.
Before draining, ensure that thepressure is released.
(1)
(2)
Before removing oil filler plug (FP),ensure that the pressure is released byopening an air outlet valve.
No external force may be applied to theair outlet valve(s), e.g. by pulling hosesor by connecting equipment directly tothe valve(s).
Do not switch the fuel selecting leverwhen the unit is in operation!
- 29 -
STARTING / STOPPING
Safety precautions
Make sure the fuel tank is filled up when“INTERNAL FUEL” is selected.
CONTROL PANEL
Do not disconnect power supply tocontrol box in any way when the controlbox is switched on. This will causememory loss.Do not switch off the circuit breakerwhen the control box is switched on. Thiswill cause memory loss.
When the compressor is put in operationfor the first time and after running out offuel or changing the fuel filter, follow thespecific start procedure as described insection Specific start procedure.
(1)(2)
(3)(4)
(5)
(F1)
(F2)
(6)
(O)
(I)
(ON/OFF)
Reference Name1 Emergency stop2 Display (4 rows, 40 characters / row)3 Pressure gauge4 Arrow Up button5 Arrow Down button6 Fuel level gaugeF1 F1 Function buttonF2 F2 Function buttonO Stop buttonI Start buttonON/OFF Power ON/OFF switch
- 30 -
OPERATIONS OVERVIEW
It is possible to control the compressor locally withthe Control Box, remotely with the remote switchinputs located on the back of the Control Box, or withsoftware running on a PC with a CAN interface (PCControl Mode).The way one ends up in each status can differ fromhow the Control Box is controlled, but the function ofeach status stays the same.When reading this document, mind the differencebetween a status and a procedure. A status is a state inthe Control Box's operation. A procedure is an actionexecuted by the Control Box.Example: The Stopping procedure is executed in theStopping status, the Start Failure status and theShutdown status.
During operation
Regularly carry out following checks:1. That the regulating valve (RV) is correctly
adjusted, i.e. starts decreasing the engine speed when reaching the preset working pressure in the 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 compressor is not in use this switch mustalways be in the “OFF” position.It is not allowed to use this switch as an emergencyswitch or for stopping the compressor. It will causedamage in the control unit when using this switch forstopping.Always first shut off the control unit and wait until thedisplay is dark before switching the battery switch toposition “OFF”.
The doors must be closed duringoperation and may be opened for shortperiods for inspection and adjustmentsonly.
Please be aware that the (optional)preheater unit is still “live” with thebattery switch in “OFF” position.
- 31 -
SPECIFIC START PROCEDURE
Follow this start procedure when the compressor isput in operation for the first time and after running outof fuel or changing the fuel filter.• 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 screw, and air is completely removed from the fuel system.
• Fasten the vent screw (1).• Switch the “ON/OFF” switch to position ”ON”.
The instrument panel will now perform 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 thefuelpump on the fuelfilter to fill thefuelsystem. Loosen the vent screw (1) onthe fuel filter. Operate the hand pump(2) at the filter until fuel comes out of thebore for the vent screw, and air iscompletely removed from the fuelsystem. Fasten the vent screw (1).When under pressure the engine willstart after approximately 10 seconds. Ifthe system is not under pressure, it willtake a few minutes untill the engine willstart.
- 32 -
POWER ON / OFF
Switch on the battery switch.Switch the machine on by switching the “ON/OFF”switch to the position “ON”. The instrument panelwill now perform a brief selftest.The display will show:
By pressing the button “F1”, the user goes to theINFO status.
STARTING
Press the button “I”. During the starting procedure thedisplay will show:
The system will automatically make 1 attempt to startthe engine. The attempt will be indicated on thedisplay as: '1/1'.
If the engine failed to start the display will show thecause of the failure:
When the stopping procedure has ended, the timemessage disappears and the F1 function appears(Reset). The display will show:
(F1)
(ON/OFF)
Do not disconnect power supply duringoperation.When disconnecting power supplyduring operation the user will beprompted to this by the next display.
(O)
(I)
To cool down the starting motor, thesystem will wait 1 minute before the nextattempt can be made, meanwhile do notleave the compressor.
- 33 -
WARMING UP
When the engine started, the Control Box executesfollowing Warm-up procedure.The engine keeps running at the Minimum RPM, untilthe Coolant Water Temperature has reached theWarm-up Temperature setting (40°C / 104°F).The display will show:
If the button “F1” is pressed during the warm-upprocess the engine will first warm-up beforeautomatically switching to LOAD.The display will show:
If the button “F1” is pressed after warming up, thecompressor immediately will enter the LOAD status.The pressure will rise till it the reaches setting.If the Warm-up Temperature has not been reachedafter 5 minutes, the Warm-up procedure will beended, and the Control Box will proceed to the NOTLOADED status.
After warming up the engine will run idle.The engine rpm is shown on the display.The display will show:
or
For entering the LOAD status the button “F1” has tobe pressed.
LOADING
By pressing the button “F1” the compressor will beloaded.The pressure will rise till it reaches the setting.
The engine rpm is shown on the display.The display will show:
The setting of the regulating valve withshut valves should be 2 bar (29 psi)higher than the required workingpressure.
(F1)
- 34 -
FAULT CODES
There are several parameters that are continuouslywatched.When one of these parameters exceeds its specifiedlimit the compressor will react depending the presentstatus of the control box.
The message displayed can be a warning, a shut downor a start failure.
Display text Warning Shutdown Start FailureFUEL LEVEL SENSOR FAILURE X X XVESSEL PRESSURE SENSOR FAILURE X X XREGULATING PRESSURE SENSOR FAILURE X X XLP ELEMENT TEMPERATURE SENSOR FAILURE X X XHP ELEMENT TEMPERATURE SENSOR FAILURE X X XLOADING VALVE FAILURE X X XCAN J1939 COMMUNICATION FAILURE X X XSTARTER RELAY FAILURE X XENGINE NOT RESPONDING X XSTARTER MOTOR BURNING DANGER X XENGINE OVERSPEED PROTECTION X XAMBIENT TEMPERATURE SENSOR FAILURE XINTERSTAGE PRESSURE SENSOR FAILURE XFLASH LIGHTS FAILURE XHORN FAILURE XOPERATING ON DEFAULT PARAMETERS XFUEL LEVEL TOO LOW X X XLP ELEMENT TEMPERATURE TOO HIGH X X XHP ELEMENT TEMPERATURE TOO HIGH X X XCOOLANT LEVEL TOO LOW X X XVESSEL PRESSURE TOO HIGH TO START X XVESSEL PRESSURE TOO LOW TO LOAD XVESSEL PRESSURE TOO HIGH X XFUEL LEVEL LOW XLP ELEMENT TEMPERATURE HIGH XHP ELEMENT TEMPERATURE HIGH XCOOLANT LEVEL LOW X
- 35 -
BATTERY VOLTAGE LOW XBATTERY NOT CHARGING XCHECK AIRFILTERS XAMBIENT TEMPERATURE HIGH XENGINE COOLANT TEMP. SENSOR FAILURE X X XENGINE OIL PRESSURE SENSOR FAILURE X X XENGINE FUEL PRESSURE SENSOR FAILURE X X XENGINE FUEL TEMPERATURE SENSOR FAILURE X X XENGINE FUEL TEMPERATURE TOO HIGH X X XENGINE FUEL PRESSURE TOO LOW X X XENGINE COOLANT TEMPERATURE TOO HIGH X X XENGINE INJECTOR X FAILURE X X XENGINE ADM MODULE FAILURE X X XENGINE OIL PRESSURE TOO LOW X XENGINE OIL TEMPERATURE SENSOR FAILURE XENGINE AIR INLET TEMP. SENSOR FAILURE XENGINE AIR INLET TEMPERATURE HIGH XENGINE TURBO BOOST PRESS. SENSOR FAILURE XENGINE TURBO BOOST PRESSURE HIGH X
OptionsCOLDSTART RELAY FAILURE XAFTERCOOLER AIR DISCHARGE TEMP HIGH XAMBIENT TEMP TOO COLD FOR AFTERCOOLER XAFTERCOOLER AIR DISCHARGE TEMP TOO HIGH X XAFTERCOOLER AIR DISCH PRESS SENSOR FAIL XAFTERCOOLER AIR DISCH TEMP SENSOR FAIL XAIR SHUT-OFF VALVE RELAY FAILURE XBLOW-OFF VALVE FAILURE XAIR DISCHARGE TEMPERATURE HIGH XAIR DISCHARGE TEMPERATURE TOO HIGH X XAIR DISCHARGE TEMPERATURE SENSOR FAILURE XAIR DISCHARGE PRESSURE SENSOR FAILURE X
Display text Warning Shutdown Start Failure
- 36 -
When the compressor is shut down because ofexceeding a parameter setting (e.g. compressortemperature) the display shows:
and than:
After the stopping procedure has ended press F1 tocontinue.Restarting before the parameter is within its limits isimpossible because of the parameter check before thecranking procedure.
STOPPING
To turn off the compressor first press the button “0”.The engine will run some time at min. speed to cooldown and will stop finally. The remaining time is shown in the display:
Meanwhile the air receiver is depressurised.Switch the “ON/OFF” switch to the position “OFF”.Wait until the display is dark.Switch the battery switch in the “OFF” position.
STARTING / STOPPING VIA REMOTE CONTROL
(O)
(ON/OFF)
Always use the remote control functionin accordance to local/work arealegislation.
1 Start Engine
2 Stop Engine
3 Load/unload compressor
(3)
(1)
(2)
- 37 -
EMERGENCY STOP
When an emergency stop button (1) is pressed, powerto all outputs is terminated, by the emergency stopitself (hardware) as well as by the software.The display will show:
When the emergency stop button (1) is unlocked theoperator can reset the emergency stop by pressing thebutton “F1”.
INFO
In the Info status, the user gets information about theCompressor configuration and starting environment:
Following topics are displayed in the Options statusas an endless list. (scrolling down at the last topicdisplays the first, scrolling up at the first topicdisplays the last).Text in capitals is the text that appears on the display.(max 19 characters).
(1) (F1)
The emergency stop button is only to be used in emergency situations; not for stoppingprocedures.
(F1)
(F2)
- 38 -
The characters XXXX XXXX in the upper rightcorner stand for compressor type.
• COMPRESSOR TYPE
• CONTROL MODE
• BATTERY VOLTAGE
• AMBIENT TEMPERATURE
• SOFTWARE VERSION
• COMPR. SERIAL NR
• ENGINE SERIAL NR
• FLEET NR (Optional)
The “F2” button returns to “READY TO START”.
OPTIONS
The operator can select following settings:
• Language
• Pressure Units (Metric / Imperial)
• Temperature Units (Kelvin / °C / °F)
• Flow Units (Metric / Imperial)
• Service (confirming service taks)
• Horn at start (enable / disable Horn during Start Warning Time)
• Tests (activating certain tests)
• History (viewing shutdown history)
• Electric refuel pump
• Remote start
• Aftercooler and bypass
• Regulating system dual pressure no fuel expert
• Regulating system dual pressure fuel expert
The “F1” button enters a menu, or confirms a newparameter setting.To select a menu, the button function text is“F1:SELECT”.To go back, the button function text is “F2:BACK”.
If the “F1” button is pressed, the topic next to ">" isselected.For example, if the operator wishes to change thelanguage to "NEDERLANDS", he would press the“F1” button when "LANGUAGE" is next to ">".From there the operator has entered the languagemenu. The present value is displayed under“LANGUAGE”.Then he scrolls to "NEDERLANDS" and presses the“F1” button.The display will show:
- 39 -
ELECTRIC REFUEL PUMP (OPTION)
The fuel pump can be activated in the options status.When “FUEL PUMP” is selected a second menuallows the user to activate (“ON”) or deactivate(“OFF”) the fuel pump.When switched on the electric refuel pump willautomatically be switched off when:• the tank is full,• the tank from which is being refueled is empty,• when leaving the “FUEL PUMP” menu by
selecting “EXIT” or pressing “F2:BACK”.
SERVICE TASK CONFIRMED
The following confirmation is displayed for 10seconds, or until the “F1” button is pressed.
When the display shows the Option status again theservice task that has been confirmed is no longerdisplayed (because it is confirmed).
SERVICE IN ADVANCE
When “SERVICE IN ADVANCE” is selected theuser enters a submenu.If the next standard service task is due within 50running hours, the user can choose “NEXT SERVICETASK”.
Next to the next standard service task all activecustom service tasks are always displayed.When a service task is selected (pressing the button“F1”), this service task is triggered and confirmed.This confirmation is also displayed.When pressing the button “F2”, “EXIT”, the usergoes straight to “READY TO START”.
The electric fuel pump may only be usedwhen the compressor is not running.
(F1)
(F2)
- 40 -
MaintenanceLIABILITY
The manufacturer does not accept any liability for anydamage arising from the use of non-original parts andfor modifications, additions or conversions madewithout the manufacturer’s approval in writing.
SERVICE PAKS
A Service Pak is a collection of parts to be used for aspecific maintenance task, e.g. after 50, after 500 andafter 1000 running hours.It guarantees that all necessary parts are replaced atthe same time keeping down time to a minimum.The order number of the Service Paks are listed in theAtlas Copco Parts List (ASL).
Use of service paksService Paks include all genuine parts needed fornormal maintenance of both compressor and engine.Service Paks minimize downtime and keep yourmaintenance budget low.Order Service Paks at your local Atlas Copco dealer.
SERVICE KITS
A service kit is a collection of parts to fit a specificrepair or rebuilding task.It guarantees that all necessary parts are replaced atthe same time which improves the uptime of the unit.The order numbers of the Service Kits are listed in theAtlas Copco Parts List (ASL).
STORAGE
Run the compressor regularly, e.g. twice a week, untilwarm.Load and unload the compressor a few times tooperate the unloading and regulating components.Close the air outlet valves after stopping.
SAFETY PRECAUTIONS
Contact Atlas Copco.
If the compressor is going to be storedwithout running from time to time,protective measures must be taken.
Before performing any maintenancejobs always put the battery switch in the“OFF” position. See section Batteryswitch.Always observe the applicable safetyprecautions. See section Safety duringmaintenance and repair.Please note that when the battery switchis off there can still be some parts live!
- 41 -
PREVENTIVE MAINTENANCE SCHEDULE FOR THE COMPRESSOR
The schedule contains a summary of the maintenanceinstructions. Read the respective section before takingmaintenance measures.When servicing, replace all disengaged packings, e.g.gaskets, O-rings, washers.For engine maintenance refer to Engine OperationManual.
The maintenance schedule has to be seen as aguideline for compressors operating in a dustyenvironment typical to compressor applications.Maintenance schedule can be adapted depending onapplication, environment and quality of maintenance.
Maintenance schedule Daily 50 hours after initial start-up
Every 6 months or 500 hours
Yearly or every 1000 hours
Service pakXRYS 557 Cd - XRYS 1220 CD7 2912 6075 05 2912 6408 06
XRXS 567 Cd - XRXS 1240 CD7XRXS 607 Cd - XRXS 1275 CD7 2912 6075 05 2912 6076 06
XRVS 617 Cd - XRVS 1300 CD7XRVS 647 Cd - XRVS 1350 CD7 2912 6075 05 2912 6075 06
Engine oil level CheckCondensate (11) DrainCompressor oil level CheckCoolant level CheckAir filter vacuator valves EmptyFuel filter water drain DrainABS vessel drain DrainElectrolyte level and terminals of battery Check Check CheckTyre pressure Check Check CheckLeaks in air-, oil- or fuel system (13) Check Check CheckOil cooler Clean Clean(to be continued on page 43)
- 42 -
Maintenance schedule(continuation of page 42)
Daily 50 hours after initial start-up
Every 6 months or 500 hours
Yearly or every 1000 hours
Radiator Clean CleanIntercooler Clean CleanTorque of wheel nuts Check Check CheckBrake system (if installed) Check/Adjust Check/Adjust Check/AdjustSafety valve (10) TestDoor hinges Grease GreaseTowing eye shaft or ball coupling and shaft Grease GreaseBleed-off valve unloader ReplaceOil stop valve CleanRubber flexibles (13) CheckShut-down switches CheckPressure drop over oil separator element (2) Replace/MeasureFan V-belts (3) Adjust Adjust AdjustFuel tank Clean CleanCompressor oil (1) (8) ChangeCompressor oil filter (6) Replace ReplaceCoolant (9) (5) AnalyseAir filter element (1) ReplaceEngine oil (3) (4) Change ChangeEngine oil filter (3) Replace ReplacePrimary fuel filter (AC filter) (7) Replace ReplaceFuel prefilter (3) (7) Replace ReplaceCrankcase breather filter Clean Clean(to be continued on page 44)
- 43 -
Notes
Maintenance schedule(continuation of page 43)
Daily 50 hours after initial start-up
Every 6 months or 500 hours
Yearly or every 1000 hours
Fuel filter (3) (7) Replace ReplaceEngine inlet and outlet valves (3) (12) Adjust AdjustFlow restrictor in oil scavenge line CleanExternal fuel connection CheckInspection by Atlas Copco Service Technician Inspection
1. More frequently when operating in a dusty environment.2. Replace the element when the pressure drop exceeds 0.8 bar (11.6 psi).3. Refer to the engine operation manual.4. 200 / 500 hours is only valid when using PAROIL 15W40.5. Check coolant every year. Change coolant every 5 years.6. Use Atlas Copco oil filters, with by-pass valve, as specified in the parts list.7. Replace the fuel filters regularly. Gummed or clogged filters mean fuel starvation and reduced
engine performance. The quality of the fuel determines the frequency of renewal.8. See section Oil specifications.9. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing
point:• 2913 0028 00 refractometer• 2913 0029 00 pH meter.
10. See section Safety valve.11. See section Before starting.12. The engine inlet and outlet valves initially need to be adjusted at 500 hours.13. Replace all rubber flexibles each 6 years, according to DIN 20066.
Keep the bolts of the housing, the liftingbeam, tow bar and axles securelytightened. For torque values see sectionTechnical specifications.
- 44 -
OIL SPECIFICATIONS
High-quality, mineral, hydraulic or synthesizedhydrocarbon oil with rust and oxidation inhibitorsanti-foam and anti-wear properties is recommended.
It is strongly recommended to use AtlasCopco branded lubrication oils for bothcompressor and engine.
Only use synthetic compressor oil.
Never mix synthetic with mineral oil.Remark:When changing from mineral tosynthetic oil (or the other way around),you will need to do an extra rinse:After doing the complete changeprocedure to synthetic oil, run the unitfor a few minutes to allow good andcomplete circulation of the synthetic oil.Then drain the synthetic oil again andfill again with new synthetic oil. To setcorrect oil levels, proceed as in normalinstruction.
COMPRESSOR OIL
Synthetic compressor oil PAROIL S
Synthetic compressor oil PAROIL S68
Liter US gal Imp gal cu.ft Order numbercan 5 1.3 1.1 0.175 1615 5950 01can 20 5.3 4.4 0.7 1615 5951 01barrel 210 55.2 46 7.35 1615 5952 01container 1000 265 220 35 1604 7422 00
Liter US gal Imp gal cu.ft Order numbercan 20 5.3 4.4 0.7 1604 7136 00barrel 210 55.2 46 7.35 1604 7137 00
The viscosity grade should correspond to the ambient temperature and ISO 3448, as follows:
Type of lubricant Compressor Enginebetween -25°C (-13°F) and +30°C (86°F) PAROIL S PAROIL 5W40between -10°C (14°F) and +30°C (86°F) PAROIL S PAROIL 15W40between -10°C (14°F) and +50°C (122°F) PAROIL S68 PAROIL 15W40
- 45 -
ENGINE OIL
PAROIL from Atlas Copco is the ONLY oil testedand approved for use in all engines built into AtlasCopco compressors and generators.Extensive laboratory and field endurance tests onAtlas Copco equipment have proven PAROIL tomatch all lubrication demands in varied conditions. Itmeets stringent quality control specifications toensure your equipment will run smoothly andreliably.The quality lubricant additives in PAROIL allow forextended oil change intervals without any loss inperformance or longevity.PAROIL provides wear protection under extremeconditions. Powerful oxidation resistance, highchemical stability and rust- inhibiting additives helpreduce corrosion, even within engines left idle forextended periods.
PAROIL contains high quality anti-oxidants tocontrol deposits, sludge and contaminants that tend tobuild up under very high temperatures. PAROIL'sdetergent additives keep sludge forming particles in afine suspension instead of allowing them to clog yourfilter and accumulate in the valve/rocker cover area.PAROIL releases excess heat efficiently, whilstmaintaining excellent bore-polish protection to limitoil consumption.PAROIL has an excellent Total Base Number (TBN)retention and more alkalinity to control acidformation.PAROIL prevents Soot build-upPAROIL is optimized for the latest low emissionEURO -3 & -2, EPA TIER II & III engines running onlow sulphur diesel for lower oil and fuel consumption.
PAROIL 5W40 is a Synthetic ultra high performancediesel engine oil with a high viscosity- index. AtlasCopco PAROIL 5W40 is designed to provideexcellent lubrication from start-up in temperatures aslow as -25°C (-13°F). PAROIL 15W40 is a mineralbased high performance diesel engine oil with a highviscosity- index. Atlas Copco PAROIL 15W40 isdesigned to provide a high level of performance andprotection in 'standard' ambient conditions as from-15°C (5°F).
Synthetic engine oil PAROIL 5W40
Mineral engine oil PAROIL 15W40
Liter US gal Imp gal cu.ft Order numbercan 5 1.3 1.1 0.175 1604 6060 00can 20 5.3 4.4 0.7 1604 6059 00
Liter US gal Imp gal cu.ft Order numbercan 5 1.3 1.1 0.175 1615 5953 00can 20 5.3 4.4 0.7 1615 5954 00barrel 210 55.2 46 7.35 1615 5955 00
- 46 -
OIL LEVEL CHECK
CHECK ENGINE OIL LEVEL
Also consult the Engine Operation Manual for the oilspecifications, viscosity recommendations and oilchange intervals.For intervals, see Preventive maintenance schedulefor the compressor.Check engine oil level according to the instructions inthe Engine Operation Manual and if necessary top upwith oil.
CHECK COMPRESSOR OIL LEVEL
With the compressor standing horizontal, check thelevel of the compressor oil.The pointer of the oil level gauge (1) must register inthe upper extremity of the green range. Add oil ifnecessary.
Before removing the oil filler plug (2),ensure that the pressure is released byopening an air outlet valve (3).
(3)
(1)
(2)
- 47 -
OIL AND OIL FILTER CHANGE
ENGINE OIL AND OIL FILTER CHANGE
See section Preventive maintenance schedule forthe compressor.
TOPPING UP THE COMPRESSOR OIL
1. Stop the compressor. Wait a few minutes 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).
COMPRESSOR OIL AND OIL FILTER CHANGE
The quality and the temperature of the oil determinethe oil change interval.The prescribed interval is based on normal operatingconditions and an oil temperature of up to 100 °C(212 °F) (see section Preventive maintenanceschedule for the compressor).When operating in high ambient temperatures, in verydusty or high humidity conditions, it is recommendedto change the oil more frequently.
(2)(1)
In this case, contact Atlas Copco.
(4)
(3)
(1)
(2)
- 48 -
1. Run the compressor until warm. Close the outlet valve(s) (3) and stop the compressor. Wait until the pressure is released through the automatic blow-down valve. Unscrew the oil filler plug (2) one turn. This uncovers a vent hole, which permits any pressure in the system to escape.
2. Drain the compressor oil by removing all relevant drain plugs (4). Catch the oil in a drain pan. Screw out the filler plug (2) to speed up draining. After draining, place 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 contacts its seat, then tighten one half turn only.
5. Fill the air receiver until the pointer of the oil level gauge is in the upper part of the green area. Be sure that no dirt gets into the system. Reinstall and tighten the filler plug.
6. Start the compressor and let it run unloaded for a few minutes.
7. Stop the compressor, wait a few minutes and top up with oil until the pointer of the oil level gauge is in the upper part of the green area.
COOLANT SPECIFICATIONS
The use of the correct coolant is important for goodheat transfer and protection of liquid-cooled engines.Coolants used in these engines must be mixtures ofgood quality water (distilled or de-ionised), specialcoolant additives and if necessary freeze protection.Coolant that is not to manufacturer's specification willresult in mechanical damage of the engine.The freezing point of the coolant must be lower thanthe freezing point that can occur in the area. Thedifference must be at least 5 °C (9 °F). If the coolantfreezes, it may crack the cylinder block, radiator orcoolant pump.Consult the engine's operation manual and follow themanufacturer's directions.
Never add more oil. Overfilling results inoil consumption.
Never remove the cooling system fillercap while coolant is hot.The system may be under pressure.Remove the cap slowly and only whencoolant is at ambient temperature. Asudden release of pressure from a heatedcooling system can result in personalinjury from the splash of hot coolant.
It is strongly recommended to use AtlasCopco branded coolant.
Never mix different coolants and mix thecoolant components outside the coolingsystem.
- 49 -
PARCOOL EG
PARCOOL EG is the only coolant that has beentested and approved by all engine manufacturerscurrently in use in Atlas Copco compressors andgenerators.Atlas Copco's PARCOOL EG extended life coolant isthe new range of organic coolants purpose designedto meet the needs of modern engines. PARCOOL EGcan help prevent leaks caused by corrosion.PARCOOL EG is also fully compatible with allsealants and gasket types developed to join differentmaterials used within an engine.
PARCOOL EG is a ready to use Ethylene Glycolbased coolant, premixed in an optimum 50/50dilution ratio, for antifreeze protection guaranteed to-40°C (-40°F).Because PARCOOL EG inhibits corrosion, depositformation is minimized. This effectively eliminatesthe problem of restricted flow through the enginecoolant ducts and the radiator, minimizing the risk forengine overheating and possible failure.It reduces water pump seal wear and has excellentstability when subjected to sustained high operatingtemperatures.
PARCOOL EG is free of nitride and amines to protectyour health and the environment. Longer service lifereduces the amount of coolant produced and needingdisposal to minimise environmental impact.
PARCOOL EG
To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additivesin the coolant must be kept between certain limits, as stated by the manufacturer's guidelines. Topping up thecoolant with water only, changes the concentration and is therefore not allowed.Liquid-cooled engines are factory-filled with this type of coolant mixture.
PARCOOL EG Concentrate
Liter US gal Imp gal cu.ft Order numbercan 5 1.3 1.1 0.175 1604 5308 00can 20 5.3 4.4 0.7 1604 5307 01barrel 210 55.2 46 7.35 1604 5306 00
Liter US gal Imp gal cu.ft Order numbercan 5 1.3 1.1 0.175 1604 8159 00
- 50 -
HANDLING PARCOOL EG
PARCOOL EG should be stored at ambienttemperatures, while periods of exposure totemperatures above 35 °C (95 °F) should beminimized. PARCOOL EG can be stored for aminimum of 5 years in unopened containers withoutany effect on the product quality of performance.PARCOOL EG is compatible with most othercoolants based on ethylene glycol, but you only getthe benefits of 5 years protection when its used on itsown. Exclusive use of PARCOOL EG isrecommended for optimum corrosion protection andsludge control.For simple density-measuring of Ethylene Glycol andPropylene Glycol in general the standard available‘density’ measuring devices are used to measure theconcentration of EG. In case a device is used tomeasure EG, no PG can be measured afterwards as aresult of the difference in the density. More specificmeasurements can be done by the use of arefractometer. This device can measure both EG andPG. A mix of both products will be show unreliableresults!Mixed EG coolants with identical glycol type can bemeasured by use of a refractometer as well as the‘density’ system. The mixed coolants will beconsidered as one product.The use of distilled water is recommended. If youhave exceptionally soft water it would be acceptable,as well. Basically, the engine metals are going tocorrode to some extent no matter what water you use,and hard water will encourage the resulting metalsalts to precipitate.PARCOOL EG comes as a pre-mixed coolant tosafeguard the quality of the complete product.It is recommended that topping up of the coolingsystem is always done with PARCOOL EG.
COOLANT CHECK
In order to guarantee the lifetime and quality of theproduct, thus to optimise engine protection, regularcoolant-condition-analysis is advisable.The quality of the product can be determined by threeparameters:
Visual check• Verify the outlook of the coolant regarding colour
and make sure that no loose particles are floating around.
pH measurement• Check the pH value of the coolant using a pH-
measuring device.• The pH-meter can be ordered from Atlas Copco
with part number 2913 0029 00.• Typical value for EG = 8.6.• If the pH-level is below 7 or above 9.5, the coolant
should be replaced.
Glycol concentration measurement• To optimise the unique engine protection features
of the PARCOOL EG the concentration of the Glycol in the water should be always above 33 vol.%.
• Mixtures with more than 68 vol.% mix ratio in water are not recommended, as this will lead to high engine operating temperatures.
• A refractometer can be ordered from Atlas Copco with part number 2913 0028 00.
TOPPING UP/REPLACING COOLANT
• Verify if the engine cooling system is in a good condition (no leaks, clean,...).
• Check the condition of the coolant.• If the condition of the coolant is outside the limits,
the complete coolant should be replaced (see section Replacing the coolant).
• Always top-up with PARCOOL EG Concentrate / PARCOOL EG.
• Topping up the coolant with water only, changes the concentration of additives and is therefore not allowed.
Never remove the cooling system fillercap while coolant is hot.The system may be under pressure.Remove the cap slowly and only whencoolant is at ambient temperature. Asudden release of pressure from a heatedcooling system can result in personalinjury from the splash of hot coolant.
In case of a mix of different coolantproducts this type of measurementmight provide incorrect values.
- 51 -
TOPPING UP WITHOUT DRAINING FROM THE COOLING SYSTEM
The quantity of PARCOOL EG Concentrate to be topped up can be estimated with the following formula and/or graph:
Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate
14
33
33 17 14 50 4,850- = =* /
40,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
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 befilled without draining from the cooling system.
1. Refractometer indication -20° C (33%)2. Refractometer indication -22° C3. Refractometer indication -25° C4. Refractometer indication -30° C5. Refractometer indication -36° C
LiterVol %
Liter PARCOOL EG Concentrate
Engine coolant capacity (liter)
Top-up volume PARCOOL EG Concentrate without drainage
Top
-up
volu
me
(lite
r)
PN: 1604 8159 00
- 52 -
TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEM
The quantity of PARCOOL EG Concentrate to be topped up after draining a calculated volume from the cooling system, can be estimated with the following formula and/or graph:Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate
80
33
33
33
17
67
80 67 2050-
100-
= =* /
=
Example:Total volume coolant =Measured concentration =
In case of expansion tank at normal level, this quantity is tobe drained from the cooling system.
1. Refractometer indication -20° C (33%)2. Refractometer indication -22° C3. Refractometer indication -25° C4. Refractometer indication -30° C5. Refractometer indication -36° C
LiterVol %
Liter PARCOOL EG Concentrate
PN: 1604 8159 00
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 840,0
2,5
5,0
7,5
10,0
12,5
15,0
17,5
20,0
22,5
25,0
1
2
3
4
5
Engine coolant capacity (liter)
Top-up volume PARCOOL EG Concentrate without drainage
Top
-up
volu
me
(lite
r)
- 53 -
REPLACING THE COOLANT
Drain• Completely drain the entire cooling system.• Used coolant must be disposed or recycled in
accordance with laws and local regulations.
Flush• Flush twice with clean water. Used coolant must
be disposed or recycled in accordance with laws and local regulations.
• From the Atlas Copco Instruction book, determine the amount of PARCOOL EG required and pour into the radiator top tank.
• It should be clearly understood that the risk for contamination is reduced in case of proper cleaning.
• In case a certain content of ‘other’ coolant remains in the system, the coolant with the lowest properties influences the quality of the ‘mixed’ coolant.
Fill• To assure proper operation and the release of
trapped air, run the engine until 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 thecooling efficiency.Service doors (4) are provided on both sides of the fancowl to allow easy access to the fan side surface of thecoolers.
Clean by air jet in the direction of the arrow.
Steam cleaning in combination with a cleansing agentmay be applied (do not use jet at max. power).
Close the service door(s).
Caution: do not top off when the engineis hot.
Remove any dirt from the coolers with afibre brush. Never use a wire brush ormetal objects.
(1)
(2)
(3)
(4)
To avoid damaging the coolers, anglebetween jet and coolers should beapprox. 90 °.
Protect the electrical and controllingequipment, air filters, etc. againstpenetration of moisture.Never leave spilled liquids such as fuel,oil, coolant and cleansing agents in oraround the compressor.
- 54 -
BATTERY CARE
If the battery is still dry, it must be activated asdescribed in section Activating a dry-chargedbattery.The battery must be in operation within 2 monthsfrom being activated; if not, it needs to be rechargedfirst.
ELECTROLYTE
Electrolyte in batteries is a sulphuric acid solution indistilled water.The solution must be made up before beingintroduced into the battery.
ACTIVATING A DRY-CHARGED BATTERY
• Take out the battery.• Battery and electrolyte must be at equal
temperature above 10 °C (50 °F).• Remove cover and/or plug from each cell.• Fill each cell with electrolyte until the level
reaches the mark on the battery. If there is no mark on the battery, the level must be above the plates for at least 10 mm (0.4 in) to 15 mm (0.6 in).
• Rock the battery a few times so that possible air bubbles can escape; wait 10 minutes and check the level in each cell once more; if required, add electrolyte.
• Refit plugs and/or cover.• Place the battery in the compressor.
RECHARGING A BATTERY
Before and after charging a battery, always check theelectrolyte level in each cell; if required, top up withdistilled water only. When charging batteries, eachcell must be open, i.e. plugs and/or cover removed.
Apply with preference the slow charging method andadjust the charge current according to the followingrule of thumb:Battery capacity in Ah divided by 20 gives safecharging current in Amp.
BATTERY MAINTENANCE
• Keep the battery clean and dry.• Keep the electrolyte level above the plates or at
the indicated level. Level above plates at least 10 mm (0.4 in) to 15 mm (0.6 in). Top up with distilled water only.
• Keep the terminals and clamps tight, clean, and lightely covered with petroleum jelly.
COMPRESSOR ELEMENT OVERHAUL
When a compressor element is due for overhaul, itneeds to be done by Atlas Copco. This guarantees theuse of genuine parts and correct tools with care andprecision.
Before handling batteries, read therelevant safety precautions and actaccordingly.
Read the safety instructions carefully.
Always pour the sulphuric acid carefullyinto the distilled water; never pour thewater into the acid. Use a commercial automatic battery
charger according to its manufacturer’sinstructions.
- 55 -
Adjustments and servicing proceduresSingle pressure systemThe working pressure is determined by the tension ofthe spring in the regulating valve (RV). This tensioncan be increased to raise the pressure and decreased tolower it by turning the adjusting wheel clockwise andanti-clockwise respectively.To adjust the normal working pressure, proceed asfollows:1. Loosen the lock nut of the regulating valve.2. Release Regulating Valve (turn out).3. With the outlet valves (AOV) closed, adjust the
regulating valve (RV), until a pressure is reached of nominal pressure + 2 bar (+ 29 psi).
4. Lock the regulating valve (RV) by fixing the lock nut.
Dual pressure system (option for XRXS andXRYS)The dual pressure system has two regulating valvesmarked with I and II and a switch at the rear forselecting the lower (I) or higher (II) workingpressure.Set the regulating valve (RV) marked with I at aworking pressure lower than the regulating valvemarked with II. This means the handle of RV I shouldbe scewed in less than the handle of RV II. Thispressure setting is very important. When doneotherwise the system will not work correctly.When RV I is set at a working pressure of maximum25 bar (363 psi), the rpm will increase to 1900 rpm(instead of 1800 rpm) to deliver more FAD at this“lower” pressure. RV I can be set at a pressure higherthan 25 bar (363 psi), but then there will be no speedincrease.
ADJUSTMENT OF THE PNEUMATIC REGULATING SYSTEM
(RV)
(AOV)
(II)
(I)
(RV)
- 56 -
AIR FILTERS ENGINE / COMPRESSOR
MAIN PARTS
CLEANING THE DUST TRAP
To remove dust from the dust trap pinch the vacuatorvalve (6) several times.
The instructions apply to one air filter and should berepeated for both air filters engine and air filterscompressor.
1. Release the snap clips (1) and remove the dust trap cover (2). Clean the inside of the cover.
2. Withdraw the filter element (4) and safety cartridge (3) from the housing (5).Discard the filter element when damaged.A dirty safety cartridge (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 element2. Dust trap cover 5. Filter housing3. Safety cartridge 6. Vacuator valve
The Atlas Copco air filters are speciallydesigned for the application. The use ofnon-genuine air filters may lead tosevere damage of the engine and/orcompressor elements.
(6) (1)(2) (3) (4) (5)
REPLACING THE FILTER ELEMENT AND THE SAFETY CARTRIDGE
(1)(2)
(3)
(4)
(5)
Replace the filter element and the safetycartridge at the same time. New elementsshould be inspected for tears andpunctures before installation.
The safety cartridge cannot be cleaned.
- 57 -
AIR RECEIVER
The air receiver (1) is tested according to officialstandards. Regularly have inspections carried out inconformity with local regulations.
SAFETY VALVE
Following checks must be carried out:• A check of the opening of the lifting gear, twice a
year.This can be done by screwing the cap of the valve anti-clockwise.
• A check of the set pressure once a year according to the local regulations. This check cannot be done on the compressor and must be carried out on a proper test bench.
FUEL SYSTEM
PRIMING INSTRUCTIONS
Prime the fuel system in order to fill the fuel filter.Prime the fuel system in order to purge trapped air(see paragraph Specific start procedure). The fuelsystem should be primed under the followingconditions:• Compressor is put in operation for the first time• Running out of fuel• Storage• Replacement of the fuel filterDaily drain condensate.
(2)
(1)
All adjustments or repairs are to be doneby an authorized representative of thesafety valve (2) supplier, see sectionSpecific safety precautions. Fuel leaked or spilled onto hot surfaces
or electrical components can cause a fire.To help prevent possible injury, turn the“ON/OFF” switch in position “OFF”when changing fuel filters or waterseparator elements. Clean up fuel spillsimmediately.
Do not loosen the fuel lines at the fuelmanifold. The fittings may be damagedand/or a loss of priming pressure mayoccur when the fuel lines are loosened.
- 58 -
REPLACING FILTER ELEMENTS
Replacing the filter elements:Installation instructions:1. Drain fuel from the bowl.2. Remove filter (2, 3), filterelement (4) and separate
bowl (2) from element (3).3. Apply film of gas oil to new bowl seat.4. Screw bowl (2) to new element (3) tightly by
hand.5. Apply film of gas oil to new element seals.6. Screw on filter (2, 3) and filterelement (4) tightly
by hand.7. Open head vent and operate pump (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. Take out the wire mesh and clean it in a solvent (diesel fuel).
4. Thoroughly dry the wire mesh with compressed air.
5. Put the wire mesh in the bowl and mount the bowl to the head. Do not twist hose (3).
(5)
(4)(1)
(2)
(3)
(2)
(1) (1)
(3)
- 59 -
MAINTENANCE QUICK ACTION FUEL COUPLINGS
Even with proper selection and installation, quickaction coupling life may be significantly reducedwithout a continuing maintenance program.Frequency should be determined by the severity ofthe application and risk potential. A maintenanceprogram must be established and followed by the userand must include the following as a minimum:Visual inspection of quick action couplings:Any of the following conditions require immediateshut down and replacement of the quick actioncoupling:• Cracked, damaged, or corroded quick action
coupling parts.• Leaks at the fitting, valve or mating seal.• Broken coupling mounting hardware, especially
breakaway clamps.Visual inspection all other:• Leaking seals or port connections.• Excess dirt build-up on the coupling locking
means or on the interface area of either coupling half.
• Defective clamps, guards, and shields.• Fuel level system and any entrapment.
Functional test:Operate the system at maximum operating pressureand check for possible malfunctions and freedomfrom leaks. Personnel must avoid potential hazardousareas while testing and using the system.Replacement intervals:Specific replacement intervals must be consideredbased on previous service life, government orindustry recommendations, or when failures couldresult in unacceptable downtime, damage or injuryrisk.
BRAKE ADJUSTMENTS
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 direction.
• Check the position of the brake equalizer compensators with the parking brake applied.
• Positioned at right angles to the brake rods = even play on both wheel 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.
(1)
- 60 -
BRAKE ADJUSTMENT WAGON
Adjusting the linkage• The parking brake is adjusted by using the
turnbuckle (8). Adjust till the play in the linkage is 1-3 mm (max. 3mm is allowed).
• Apply the parking brake 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).
- 61 -
Problem solvingIt is assumed that the engine is in good condition andthat there is adequate fuel flow to the filter andinjection equipment.
Make sure that the wires are not damaged and thatthey are clamped tight to their terminals.For denomination of switches, relays, etc., seeElectric system.See also section Control panel.
Problem: Compressor capacity or pressure below normal.
An electrical fault must be traced by anelectrician.
Possible faults Corrective actions
Air consumption exceeds capacity of compressor. Check equipment connected.
Choked air filter elements (AF). Remove and inspect elements. Clean or replace, if necessary.
Regulating valve (RV) defective. Have regulating valve removed and inspected by 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 Service representative.
Air intake throttle valve remains partially closed. Remove air filters, air intake manifold and throttle valve spring seat. Withdraw the valve and inspect. Replace parts where necessary. Caution: the spring seat is fixed with 4 short and 2 long setscrews: first remove the short screws, then release the spring tension unscrewing the long ones.
Safety valve (SV) leaking. Remove and inspect. Replace if not airtight after reinstallation.
Blow-off valve leaking. Remove and inspect. Replace if necessary.
- 62 -
Problem: Pressure in air receiver rises above maximum and causes safety valve to blow.
Problem: After working some time, the unit stops through a shutdown switch.
Problem: Air and oil mist expelles from air filters immediately after stopping.
Possible faults Corrective actions
Regulating valve (RV) opens too late or its ball valve spring is broken. Have regulating valve removed and inspected by an Atlas Copco Service representative.
Air leaks in regulating system. Check hoses and their fittings. Stop leaks; replace leaking hoses.
Air intake throttle valve does not close for some reason. Remove air filters, air intake manifold and throttle valve spring seat. Withdraw the valve and inspect. Replace parts where necessary. Caution: the spring seat is fixed with 4 short and 2 long setscrews: 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 contains insufficient fuel. Fill fuel tank.
Low coolant level. Top up cooling system.
Possible faults Corrective actions
Check valve at element outlet. Remove and inspect. Replace if necessary. Replace air filter elements and safety cartridges. Check the oil level and add oil if necessary. Run the compressor for a few minutes, stop and recheck oil level.
Plunger of oil stop valve jammed. Remove and inspect. Replace if necessary. Replace air filter elements and safety cartridges. Check the oil level and add oil if necessary. Run the compressor for a few minutes, stop and recheck oil level.
- 63 -
Problem: Compressor overheating.
Alternator precautions1. Never reverse the polarity of the battery or the
alternator.2. Never break any alternator or battery connections
while the engine is running.3. When recharging the battery, disconnect it from
the alternator. Before using booster cables to start the engine, be sure of the polarity and connect the batteries correctly.
4. Never operate the engine without the main or voltage sensing cables connected in the circuit.
Possible faults Corrective actions
Insufficient 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 stuck in opened position. Remove valve and check for proper opening and closing. Replace if out of order.
Fan blade(s) broken. Check and correct if necessary.
Oil stop valve malfunctioning. Remove and inspect valve.
Oil separator element (OS) clogged. Have element removed and inspected by an Atlas Copco Service representative.
- 64 -
OILTRONIX FAILURE
Manually locking the valve (temporarysolution)
Disconnect the connector (1) of the stepper motor, toensure that the stepper motor does not try to rotate thevalve.Rotate the white coupling of the valve manually untilthe blind hole (2) in the coupling is in line with thethreaded hole (3) in the housing.
Block the valve by screwing a bolt (M5 x 20) throughthe housing and in the blind hole in the coupling.
HEATER FAILURE
Problem: Heater does not start when switched on.
Problem: Flame extinghuises.
Problem: 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 again.
Possible faults Corrective actions
Upper or lower voltage limit is reached. Check power.
Possible faults Corrective actions
Device switched off and on again too many times.
Contact your agent.
Check the correct position of the blindhole with a ∅ 4 mm pin.
Contact Atlas Copco for a thorough scanand repair.
(1)
(2)
(3)
- 65 -
Available optionsUNDERCARRIAGE
The undercarriage makes it possible to move thecompressor on the site with a truck to the locationwhere it is needed. This option exits of rubber dampedaxles, four wheels and a tow bar. The wheels are alsoequipped with brakes operated from the brake handleon the tow bar.
SUPPORT MOUNTED / LARGE FUELTANKS
With the option “Support mounted” it is possible tofix the compressor to a truck for more flexibility or toa frame when it is to be used permanently in aninstallation.In combination with the support mounted it is alsopossible to integrate larger fuel tank to get largerintervals between two fuel supply actions.
SKID / LARGE FUELTANKS
The skid is ideal in circumstances where the site isimpossible to reach by truck. It allows transportationby crane or fork lift truck. When on the ground it canbe pushed into the exact location.In combination with the skid it is also possible tointegrate larger fuel tank to get larger intervalsbetween two fuel supply actions.
- 66 -
WHEEL CHOCKS
For extra safe parking on slopes.
ADDITIONAL FUELFILTER
In dusty environments or in situations where the fuelquality is not up to the normal standard, thisadditional fuel filter gives an extra protection to thefuel/combustion system.
ELECTRIC REFUEL PUMP
The electric refuel pump makes it easy to refuel thecompressor on site when refuelling from tanks orcontainers. This option also contains a suction hosewith strainer.When switched on the electric refuel pump will beautomatically switched off when:• the tank is full,• the tank from which is being refulled is empty.
- 67 -
EXTERNAL FUEL CONNECTION
When a compressor is operated on site for a longerperiod it is advisable to supply the fuel throughexternal fuel connections. When using this option theregular refuelling by tanker it is no more needed.Consequently there is also less risk for contaminationwhen refuelling.
SPARK ARRESTOR
The certified spark arrestor is an addition to theexhaust that makes it possible to operate thecompressor in hazardous environments like refinerieswhere there is a possibility that inflammable fumescan be released. The spark arrestor prevents any hot(burning) particles from getting into the open air.
PREHEATER
The preheater is a device for preheating the coolingfluid before starting when operating at lowtemperatures. The engine will start more easy.Additionally the preheater will lengthen the life spanof the engine as there are no cold starts.
- 68 -
COLD WEATHER PACKAGE
The cold start option consists of larger batteriesand a blow off valve to be able to start the engineat temperatures between -10°C (14°F) and -25°C(-13°F). It also includes a preheater.
INLET SHUTDOWN VALVE
The inlet shut down valve is a safety devicepreventing the engine from over speeding whensucking in combustible fumes. When the engine max.RPM is exceeded a pneumatically controlled solenoidvalve closes off the air inlet and the fuel supply to theengine is cut.
OILTRONIX
The OILTRONIX is an Electronic Oil ManagementSystem for compressors providing an optimal oilinjection temperature that reduces the condensationof water in the oil. This will result in a longer life ofcomponents in the compressor system.Because of the OILTRONIX the unit will also beoperating at temperatures kept as low as possible.The OILTRONIX is standard on the XRXS andXRYS types and option on the XRVS types.
- 69 -
COSMOSREMOTE MONITORING SYSTEM
COSMOS allows technicians to arrive at the rightlocation, at the right time, with the right informationand service materials so enabling you to give bettercustomer service, more up-time, and more accurateinvoicing than previously possible.
COSMOS provides information on:• time to maintenance• operational history (running hours, fuel levels,
events)• utilization data visualized in usage graphs• the location of the machine• all measured values and parameters
REGULATING SYSTEM SINGLE PRESSUREFUEL EXPERT
This is a control module that regulates engine speedand the air inlet to optimise fuel consumptiondepending on the working conditions, and the outputrequired.This option contains one regulating valve.
REGULATING SYSTEM DUAL PRESSURENO FUEL EXPERT
With this option it is possible to set the pressure totwo particular pressures.
- 70 -
REGULATING SYSTEM DUAL PRESSUREFUEL EXPERT
This option combines the dual pressure regulatingsystem with the fuel optimising system, thus savingon fuel costs.
PRESSURE REGULATOR EC
A pressure regulating system according to Europeanstandards for reducing the operating pressure. It willlimit the operating pressure to 7 bar and allow theoperation of hand held pneumatic tools.
PRESSURE REGULATOR ASME
A pressure regulating system according to USstandards for reducing the operating pressure. It willlimit the operating pressure to 7 bar and allow theoperation of hand held pneumatic tools.
- 71 -
FORK LIFT SLOTS
With fork lift slots the compressor can easily bemoved with a fork lift truck on building sites where itis impossible to use a towing truck.
AFTER-COOLER
An integral after-cooler, with water separator (1), isavailable to reduce the outlet air temperature toambient plus 10°C (18°F) and cut water content to amere 15%. The installation includes a by-pass overthe after-cooler.For applications that demand quality air, a finefiltration unit (2) can be specified with the after-cooler package. This will remove oil and particlesdown to 0.01 mg/m3.For purer, but not breathing, air, an active charcoalfiltration unit (3) can be specified with the after-cooler package. This removes oil and oil vapourcontent to 0.003 mg/m3.
(1)
(2)
(3)
- 72 -
REMOTE START
The remote start allows the user to start, stop thecompressor and switch to load/noload by radiosignal.This is particularly comfortable when the compressorcan not be positioned directly at the job site becauseof blocking by buildings or other obstacles.
INTERNAL LIGHTNING
The internal lighting circuit is equipped with a timer.When the internal lighting is switched on, the timer isstarted. After a preset time the internal light will beswitched off automatically.
- 73 -
Technical specificationsTORQUE VALUES
GENERAL TORQUE VALUES
The following tables list the recommended torques applied for general applicationsat assembly of the compressor.
For hexagon screws and nuts with strength grade 8.8
For hexagon screws and nuts with strength grade 12.9
CRITICAL TORQUE VALUES
Thread size Torque value (Nm / lbf.ft) M6 9 (7)M8 23 (17)M10 46 (35)M12 80 (60)M14 125 (93)M16 205 (152)
Thread size Torque value (Nm / lbf.ft) M6 15 (12)M8 39 (29)M10 78 (58)M12 135 (100)M14 210 (155)M16 345 (255)
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/frame 23 (17)Lifting beams to frame:Bolts, lifting beams/yoke (M12) 125 (93)Bolts, lifting beams/yoke (M16) 205 (152)Bolts, lifting beams/A-Frames 205 (152)Bolts, A-Frames/frame 205 (152)Hose clamps:Pebra hose clamps on all IC/radiator hoses
12 (9)
Secure the drain cock and tank cap of the fuel tank handtight.
- 74 -
COMPRESSOR / ENGINE SPECIFICATIONS
REFERENCE CONDITIONS
The inlet conditions are specified at the air inlet grating outside the canopy.
LIMITATIONS
Designation XRYS 557 Cd - XRYS 1220 CD7 XRXS 567 Cd - XRXS 1240 CD7XRXS 607 Cd - XRXS 1275 CD7
XRVS 617 Cd - XRVS 1300 CD7XRVS 647 Cd - XRVS 1350 CD7
Absolute inlet pressure bar(e) 1 1 1psi 14.5 14.5 14.5
Relative air humidity % 0 0 0Air inlet temperature °C 20 20 20
°F 68 68 68Nominal effective working pressure bar(e) 35 30 25
psi 508 435 363
Designation XRYS 557 Cd - XRYS 1220 CD7 XRXS 567 Cd - XRXS 1240 CD7XRXS 607 Cd - XRXS 1275 CD7
XRVS 617 Cd - XRVS 1300 CD7XRVS 647 Cd - XRVS 1350 CD7
Minimum effective receiver pressure bar(e) 22 19 16psi 319 276 232
Maximum effective receiver pressure, compressor unloaded
bar(e) 35 32 27psi 508 464 392
Maximum ambient temperature at sea level
without aftercooler
°C 50 50 50°F 122 122 122
with aftercooler
°C 45 45 45°F 113 113 113
Minimum starting temperature °C -10 -10 -10°F 14 14 14
Minimum starting temperature, with coldstart equipment
°C -25 -25 -25°F -13 -13 -13
Altitude capability see separate curve on page 78
- 75 -
PERFORMANCE DATA
At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.
Designation XRYS 557 Cd - XRYS 1220 CD7
XRXS 567 Cd - XRXS 1240 CD7
XRXS 607 Cd - XRXS 1275 CD7
XRVS 617 Cd - XRVS 1300 CD7
XRVS 647 Cd - XRVS 1350 CD7
Engine shaft speed, normal and maximum r/min 1800 1800 1900 1800 1800Engine shaft speed, compressor unloaded r/min 1300 1300 1300 1300 1300Free air delivery 1) without
aftercoolerl/s 554 566 621 606 630cfm 1,174 1,199 1,316 1,284 1,335
with aftercooler
l/s 537 549 602 588 611cfm 1,138 1,163 1,276 1,246 1,295
Fuel consumption- at 100% FAD Fuel expert kg/h 87.4 84.3 88.6 82.4 85.4
lb/h 192.7 185.8 195.3 181.7 188.3NoFuel expert
kg/h 87.4 84.3 88.6 82.4 85.4lb/h 192.7 185.8 195.3 181.7 188.3
- at 75% FAD Fuel expert kg/h 71.3 67.0 67.9 64.7 67.0lb/h 157.2 147.7 149.7 142.6 147.7
NoFuel expert
kg/h 76.1 73.9 78.5 70.0 72.5lb/h 167.8 162.9 173.1 154.3 159.8
- at 50% FAD Fuel expert kg/h 54.5 54.8 53.8 46.3 48.0lb/h 120.2 120.8 118.6 102.1 105.8
NoFuel expert
kg/h 62.4 58.9 58.3 54.6 56.6lb/h 137.6 129.9 128.5 120.4 124.8
- at 25% FAD Fuel expert kg/h 48.7 44.9 43.2 41.5 43.0lb/h 107.4 99.0 95.2 91.5 94.8
NoFuel expert
kg/h 49.0 45.1 43.2 41.9 43.4lb/h 108.0 99.4 95.2 92.4 95.7
- 76 -
1) Free air delivery is measured according to ISO 1217 ed.3 1996 annex D
- at unload Fuel expert kg/h 40.8 32.9 32.9 30.0 31.1lb/h 89.9 72.5 72.5 66.1 68.6
NoFuel expert
kg/h 40.8 32.9 32.9 30.0 31.1lb/h 89.9 72.5 72.5 66.1 68.6
Specific fuel consumption without aftercooler
g/m3 42.8 41.4 39.6 37.8 37.7lb/1000 cu.ft 2.67 2.58 2.47 2.36 2.35
with aftercooler
g/m3 44.1 42.7 40.9 38.9 38.8lb/1000 cu.ft 2.75 2.67 2.55 2.43 2.42
Typical oil content of compressed air mg/m3 free air 3 3 3 3 3oz/1000 cu.ft 0.003 0.003 0.003 0.003 0.003
Engine oil consumption (maximum) g/h 225.1 217.1 228 212 220oz/h 7.94 7.66 8.04 7.48 7.76
Compressed air temperature at outlet valve
without aftercooler
°C 100 100 100 100 100°F 212 212 212 212 212
with aftercooler
°C 35 35 35 35 35°F 95 95 95 95 95
Noise level- Sound pressure level (LP), complies with ISO 2151 under free field conditions at 7 m distance
dB(A) - - - - -
- Sound pressure level (LP), complies with EPA under free field conditions at 7 m distance
dB(A) 76 76 76 76 76
- Sound power level (LW) complies with 2000/14/EC dB(A) 104 104 104 104 104
Tolerance: • +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm)• +/- 4% 250 l/s (530 cfm) < FAD
The international standard ISO 1217 corresponds tofollowing national standards:
• British BSI 1571 part 1• German DIN 1945 Part 1• Swedish SS-ISO 1217• American ANSI PTC9
Designation XRYS 557 Cd - XRYS 1220 CD7
XRXS 567 Cd - XRXS 1240 CD7
XRXS 607 Cd - XRXS 1275 CD7
XRVS 617 Cd - XRVS 1300 CD7
XRVS 647 Cd - XRVS 1350 CD7
- 77 -
ALTITUDE UNIT PERFORMANCE CURVE
Max. allowable working pressure as a function altitude and ambient temperature.
XRYS 557 Cd - XRYS 1220 CD7
0
3 281
6 562
9 843
13.124
0
1000
2000
3000
4000
-10 0 10 20 30 40 50
14 32 50 68 86 104 122
35 bar
508 psi
Alti
tude
m
Alti
tude
ft
Temperature °F
Temperature °C
XRXS 567 Cd - XRXS 1240 CD7XRXS 607 Cd - XRXS 1275 CD7
0
3 281
6 562
9 843
13.124
0
1000
2000
3000
4000
-10 0 10 20 30 40 50
14 32 50 68 86 104 122
30 bar
435 psi
Alti
tude
m
Alti
tude
ft
Temperature °F
Temperature °C
XRVS 617 Cd - XRVS 1300 CD7XRVS 647 Cd - XRVS 1350 CD7
0
3 281
6 562
9 843
13.124
0
1000
2000
3000
4000
-10 0 10 20 30 40 50
14 32 50 68 86 104 122
25 bar
363 psi
Alti
tude
m
Alti
tude
ft
Temperature °F
Temperature °C
- 78 -
DESIGN DATA
Compressor
Engine
1) With filter change.
DesignationNumber of compression stages 2
Designation All unitsMake CaterpillarType C18Coolant LiquidNumber of cylinders 6Bore mm 145
in 5.71Stroke mm 183
in 7.2Swept volume l 18.1
cu.in 1104.5Output acc. to DIN 6271 at normal shaft speed
kW 429hp 575.3
- Load factor % 100
Designation All unitsCapacity of oil sump:- Initial fill l 60
US gal 15.85- Refill (max.) 1) l 58
US gal 15.32Capacity of cooling system l 52
US gal 13.74
- 79 -
Unit
1) Air required for engine and compressor element cooling, for combustion and forcompression.
Electric refuel pump
*) Fuel temperature max 40 °C (104 °F)
Remote control
*) Obstacles and position of user in relation to receiver (at the rear of the unit) willreduce the range.
Designation All unitsCapacity of compressor oil system
l 82US gal 21.66
Net capacity of air receiver l 143US gal 37.78
Capacity of fuel tank (standard) l 975US gal 257.6
Capacity of fuel tanks- with skid or support mounted- with option large fuel tanks
l 1550US gal 409.5
Air volume at inlet grating (approx.) 1)
m3/s 13.9cu.ft/s 491
Designation All unitsFlow rate *) l/m 50
US gal/m 13Self priming *) from dry up to m 2.4
ft 7.8
Designation All unitsRange *) m 200
ft 656
- 80 -
Compressor dimensions
Designation All unitsDimensions (overall) L x W x HWagon towbar raised m 5.40 x 2.25 x 2.51
inch 233.86 x 88.58 x 101.46Tandem EU m 6.80 x 2.53 x 3.04
inch 267.71 x 99.61 x 119.69Support mounted m 4.56 x 2.25 x 2.27
inch 179.53 x 88.58 x 89.37Skid m 4.56 x 2.25 x 2.44
inch 179.53 x 88.58 x 96.06
Designation All unitsWeight (dry)Wagon kg 7200
lb 15875Tandem EU kg 8605
lb 18971Support mounted (option large fuel tank)
kg 6555 (6685)lb 14450 (14740)
Skid (option large fuel tank) kg 6775 (6095)lb 14940 (15225)
Weight (wet, incl. fuel)Wagon kg 8200
lb 18080Tandem EU kg 10100
lb 22267Support mounted (option large fuel tank)
kg 7555 (8180)lb 16655 (18035)
Skid (option large fuel tank) kg 7775 (8400)lb 17140 (18520)
- 81 -
Dataplate1 Company code2 Product code3 Unit serial number4 Name of the manufacturer5 EEC or national type approval number6 Vehicle identification number7 Wagon undercarriage
A Maximum permitted total weight of thevehicle
B Maximum permitted front axle loadC Maximum permitted rear axle loadTandem undercarriageA Maximum permitted total weight of the
vehicleB Maximum permitted axle loadC Maximum permitted load on the towing eye
8 Model9 Working pressure10 Speed11 Engine power12 Manufacturing year13 CE mark in accordance with Machine Directive
89/392 EC14 Register number or number of notified body
(1) (2) (3)
(4)(5)(6)
(7)
(8)(9)
(10)(11)
(12)
(14)(13)
- 82 -
LegislationPARTS, SUBJECTED TO PRESSURE EQUIPMENT DIRECTIVE 97/23/EC, CAT. II AND ABOVE
Safety valve: cat. IV
Air Oil separator
Designation XRYS 557 Cd - XRYS 1220 CD7 XRXS 567 Cd - XRXS 1240 CD7XRXS 607 Cd - XRXS 1275 CD7
XRVS 617 Cd - XRVS 1300 CD7XRVS 647 Cd - XRVS 1350 CD7
Set pressure bar(e) 40 35 30psi 580 508 435
Design temperature °C 130 130 130°F 266 266 266
Designation Standard /Cold Start Equipment
Standard Cold start equipment
Design pressure bar(e) 40 35 35psi 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 143US gal 37.7 37.7 37.7Imp gal 31.5 31.5 31.5cu.ft 5 5 5
- 83 -
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
- 84 -
DisposalGENERAL
When developing products and services, Atlas Copcotries to understand, address, and minimize thenegative environmental effects that the products andservices may have, when being manufactured,distributed, and used, as well as at their disposal.Recycling and disposal policy are part of thedevelopment of all Atlas Copco products. AtlasCopco company standards determine strictrequirements.Selecting materials the substantial recyclability, thedisassembly possibilities and the separability ofmaterials and assemblies are considered as well as theenvironmental perils and dangers to health during therecycling and disposal of the unavoidable rates of notrecyclable materials.Your Atlas Copco compressor consists for the mostpart of metallic materials, that can be remelted insteelworks and smelting works and that is thereforealmost infinite recyclable. The plastic used islabelled; sorting and fractioning of the materials forrecycling in the future is forseen.
DISPOSAL OF MATERIALS
Dispose contaminated substances and materialseparately, according to local applicableenvironmental legislations.Before dismantling a machine at the end of itsoperating lifetime drain all fluids and dispose ofaccording the applicable local disposal regulations. Remove the batteries. Do not throw batteries into thefire (explosion risk) or into the residual waste.Separate the machine into metal, electronics, wiring,hoses, insulation and plastic parts. Dispose all components according to the applicabledisposal regulations.Remove spilled fluid mechanically; pick up the restwith absorbing agent (for example sand, sawdust) anddispose it according the applicable local disposalregulations. Do not drain into the sewage system orsurface water.
This concept can only succeed with yourhelp. Support us by disposingprofessionally. By assuring a correctdisposal of the product you help toprevent possible negative consequencesfor environment and health, that canoccur with an inappropriate wastehandling.Recycling and re-usage of material helpsto preserve natural resources.
- 85 -
Maintenance Log
Compressor .......................................................................................... Customer ...............................................................................................
Serial number........................................................................................ ................................................................................................................
Service hours Maintenance action Date By initials
- 86 -
1
(2)
tt’nt x
he
- 88 -
Following documents are provided with this unit:
– Test Certificate– EC Declaration of Conformity:
Atlas Copco Airpower n.v. puorG ocpoC saltA eht nihtiw ynapmoc A
Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 4465P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231 B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
evitatneserper ocpoC saltA lacol ruoy tcatnoc esaelp ,ofni roF muigleB muigleBwww.atlascopco.com
p.1
Form
5009
060
3 04
ed. 0
0, 2
010-
01-0
1
1 EC DECLARATION OF CONFORMITY 2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product 3 Machine name : Compressor (≥ 350 kW) 4 Machine type : 5 Serial number :
Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of thelaws of the Member States relating to machinery, is in conformity with the relevant Essential Health and Safety Requirements 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
Am
a. CE/32/79 tnempiuqe erusserP
b. CE/24/6002 ytefas yrenihcaM
EN ISO 12100-1 EN ISO 12100-2
EN 1012-1 EN 294 EN 349 EN 418 EN 563 EN 842 EN 953
EN 1037 EN 1050 EN 13478
d. Electromagnetic compatibility 2004/108/EC EN 61000-6-2 EN 61000-6-4
e. Low voltage equipment 2006/95/EC EN 60034
EN 60204-1 EN 60439
6
7
Atlas Copco Airpower n.v. is authorized to compile the technical file
8 The harmonized and the technical standards used are identified in the attachments hereafter
9
10 Conformity of the specification to the Directives
Conformity of the product to thespecification and by implication to t
directives11
12
13
gnirutcafunaM gnireenigne tcudorP yb deussI
14 Name15 Signature
16 Date
- 89 -
