for AC Compressors XAS 1800 JD7 Engine John Deere 6135 XAS ...€¦ · Instruction Manual for AC...

XAS 1800 JD7XAS 1800 CD7

Instruction Manual for AC Compressors English

Engine John Deere 6135Engine Caterpillar C15

ATLAS COPCO - PORTABLE ENERGY DIVISIONwww.atlascopco.com

Instruction Manual for AC Compressor

XAS 1800 JD7XAS 1800 CD7

Printed matter Nr1310 3012 83

12/2012

Original instructions

Warranty and Liability Limitation

Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts iThe manufacturer does not accept any liability for any damage arisin made without the manufacturer's approval inwriting.Neglecting maintenance or making changes to the setup of the machi .While every effort has been made to ensure that the information in th e responsibility for possible errors.

Copyright 2012, Atlas Copco Compressors LLC, RockHill SC USA.

Any unauthorized use or copying of the contents or any part thereof isThis applies in particular to trademarks, model denominations, part nu

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s not covered by Warranty or Product Liability.g from modifications, additions or conversions

ne can result in major hazards, including fire riskis manual is correct, Atlas Copco does not assum

prohibited.mbers and drawings.

Service paks..................................................... 47Service kits ...................................................... 47Storage............................................................. 47Preventive maintenance schedule.................... 48Maintenance schedule compressor .................. 48Oil specifications ............................................. 52

.1 Compressor oil ................................................. 53

.2 Engine oil ......................................................... 54Oil level check................................................. 54

.1 Check engine oil level...................................... 54

.2 Check compressor oil level .............................. 54Oil and oil filter change................................... 54

.1 Engine oil and oil filter change ........................ 54

.2 Compressor oil and oil filter change ................ 550 Compressor Oil Flushing Procedure ............... 560.1 Topping up the compressor oil......................... 541 Coolant specifications ..................................... 571.1 PARCOOL EG................................................. 571.2 Handling PARCOOL EG................................. 582 Coolant check .................................................. 583 Topping up/replacing coolant.......................... 583.1 Topping up without draining from

the cooling system............................................ 593.2 Topping up after limited quantity

draining from the cooling system..................... 603.3 Replacing the coolant....................................... 613.4 Cleaning coolers............................................... 614 Battery care...................................................... 624.1 Electrolyte ........................................................ 624.2 Activating a dry-charged battery...................... 624.3 Recharging a battery ........................................ 625 Compressor element overhaul ......................... 62

Adjustments and servicing procedures 63Adjustment of the continuous pneumatic regulating system ........................... 63Air filter engine/compressor............................ 63

.1 Main parts ........................................................ 63

.2 Cleaning the dust trap.................................. 63

.3 Air receiver ...................................................... 64Safety valve ..................................................... 64

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PrefacePlease read the following instructions carefully beforestarting to use your compressor.It is a solid, safe and reliable machine, built according tothe latest technology. Follow the instructions in thisbooklet and we guarantee you years of troublefreeoperation.Always keep the manual available near the machine.In all correspondence always mention the compressortype and serial number, shown on the data plate.The company reserves the right to make changes withoutprior notice.

Table of contents

1 Safety precautions..................................... 71.1 Introduction ........................................................ 71.2 General safety precautions ................................. 81.3 Safety during transport and installation.............. 81.4 Safety during use and operation ......................... 91.5 Safety during maintenance and repair .............. 101.6 Tool applications safety.................................... 111.7 Specific safety precautions ............................... 12

2 Leading particulars ................................ 132.1 General description........................................... 13

3 Data Plate ................................................. 133.1 Regulating system ........................................ 143.1.1 Overview................................................... 143.1.2 Air flow ............................................................ 153.1.3 Oil system......................................................... 153.1.4 Continuous pneumatic regulating

system............................................................... 163.2 Electric system................................................. 183.3 Markings and information labels..................... 26

4 Operating instructions............................ 274.1 Parking, towing and lifting instructions .......... 274.1.1 Parking instructions.......................................... 274.1.2 Towing instructions.......................................... 274.1.3 Lifting instructions ........................................... 274.2 Starting / Stopping........................................... 294.3 Before starting ................................................. 284.3.1 Battery switch................................................... 294.3.2 Control panel .................................................... 294.3.3 During operation .............................................. 374.3.4 Starting ............................................................. 334.3.5 Stopping ........................................................... 384.3.6 Emergency stop ................................................ 464.3.7 Fault codes........................................................ 44

5 Maintenance ............................................ 475.1 Liability ........................................................... 47

5.25.35.45.55.65.75.75.75.85.85.85.95.95.95.15.15.15.15.15.15.15.1

5.1

5.15.15.15.15.15.15.1

66.1

6.26.26.26.26.3

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6.4 Fuel system...................................................... 656.4.1 Priming instructions ......................................... 65

7 Problem solving ....................................... 68

8 Available options ......................................71

9 Technical specifications .......................... 729.1 Torque values .................................................. 729.1.1 General torque values ...................................... 729.1.2 Critical torque values ....................................... 729.2 Compressor / engine specifications ................. 739.2.1 Reference conditions........................................ 739.2.2 Limitations ....................................................... 739.2.3 Altitude unit performance curve ...................... 759.2.4 Performance data ............................................. 749.2.5 Design data....................................................... 76

10 Disposal..................................................... 7710.1 General............................................................. 7710.2 Disposal of materials ....................................... 77

11 Maintenance Log ..................................... 78

inary caution and due care required in handling,erating, maintenance or repair, also if not expresslyntioned in this instruction manual, is disclaimed bylas Copco.e manufacturer does not accept any liability for anymage arising from the use of non-original parts and fordifications, additions or conversions made without thenufacturer’s approval in writing.any statement in this manual does not comply withal legislation, the stricter of the two shall be applied.tements in these safety precautions should not beerpreted as suggestions, recommendations orucements that it should be used in violation of any

plicable laws or regulations.

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Safety precautions

INTRODUCTION

The policy of Atlas Copco is to provide the users of theirequipment with safe, reliable and efficient products.Factors taken into account are among others:- the intended and predictable future use of the products, and

the environments in which they are expected 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 specific informationabout 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 and possibleother equipment, which are separately sent along or arementioned on the equipment or parts of the unit.These safety precautions are general and some statementswill therefore not always apply to a particular unit.Only people that have the right skills should be allowed tooperate, adjust, perform maintenance or repair on AtlasCopco equipment. It is the responsibility of management to appointoperators with the appropriate training and skill for eachcategory of job.Skill level 1: OperatorAn operator is trained in all aspects of operating the unitwith the push-buttons, and is trained to know the safetyaspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unit thesame 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 safety

system. A mechanical technician does not work on liveelectrical 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 may carryout electrical repairs within the various enclosures of theunit. This includes work on live electrical components.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer or itsagent to perform complex repairs or modifications to theequipment.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 persons awayfrom the unit and eliminate all possible sources of dangerat 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 following list isa reminder of special safety directives and precautionsmainly applicable to Atlas Copco equipment.These safety precautions apply to machinery processingor consuming air. Processing of any other gas requiresadditional safety precautions typical to the applicationand are not included herein.Neglecting the safety precautions may endanger people aswell 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 resulting fromneglecting these precautions or by non-observance of

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To be read attentively and acted accordingly before towing, lifting, operating, performing maintenanceor repairing the compressor.

TY DURING TRANSPORT AND

ALLATION

ort of the unit has to be done by authorized/enced people.towing, lifting or transporting the compressor in

ay, the battery switch must always be in the “OFF”n! a unit, all loose or pivoting parts, e.g. doors andr, shall first be securely fastened.t attach cables, chains or ropes directly to the liftingpply a crane hook or lifting shackle meeting localregulations. Never allow sharp bends in lifting

, chains or ropes.pter lifting is not allowed.trictly forbidden to dwell or stay in the risk zonea lifted load. Never lift the unit over people ortial areas. Lifting acceleration and retardatione kept within safe limits.ore towing the unit:scertain that the pressure vessel(s) is (are) depressurized,heck the tow bar, the brake system and the towing eye.lso check the coupling of the towing vehicle,

heck the towing and brake capability of the towingehicle,heck that the tow bar, jockey wheel or stand leg is safelyocked in the raised position,scertain that the towing eye can swivel freely on the hook,heck that the wheels are secure and that the tyres are inood condition and inflated correctly,onnect the signalisation cable, check all lights andonnect the pneumatic brake couplers,ttach the safety break-away cable or safety chain to theowing vehicle,emove wheel chocks, if applied, and disengage thearking brake,heck whether springs on wheelchocks are missing orroken.tow a unit use a towing vehicle of ample capacity.er to the documentation of the towing vehicle.he unit is to be backed up by the towing vehicle,engage the overrun brake mechanism (if it is not anomatic mechanism).ver exceed the maximum towing speed of the unitnd the local regulations).

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GENERAL SAFETY PRECAUTIONS1 The owner is responsible for maintaining the unit in a

safe operating condition. Unit parts and accessoriesmust be replaced if missing or unsuitable for safeoperation.

2 The supervisor, or the responsible person, shall at alltimes make sure that all instructions regardingmachinery and equipment operation and maintenanceare strictly followed and that the machines with allaccessories and safety devices, as well as theconsuming devices, are in good repair, free ofabnormal wear or abuse, and are not tampered with.

3 Whenever there is an indication or any suspicion thatan internal part of a machine is overheated, themachine shall be stopped but no inspection covers shallbe opened before sufficient cooling time has elapsed;this to avoid the risk of spontaneous ignition of oilvapour when air is admitted.

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 other deposits.

7 To prevent an increase in working temperature, inspectand clean heat transfer surfaces (cooler fins,intercoolers, water jackets, etc.) regularly. See thePreventive maintenance schedule.

8 All regulating and safety devices shall be maintainedwith due care to ensure that they function properly.They may not be put out of action.

9 Care shall be taken to avoid damage to safety valvesand other pressure-relief devices, especially to avoidplugging by paint, oil coke or dirt accumulation, whichcould interfere with the functioning of the device.

10 Pressure and temperature gauges shall be checkedregularly with regard to their accuracy. They shall bereplaced whenever outside acceptable tolerances.

11 Safety devices shall be tested as described in themaintenance schedule of the instruction manual todetermine that they are in good operating condition.See the Preventive maintenance schedule.

12 Mind the markings and information labels on the unit.13 In the event the safety labels are damaged or destroyed,

they must be replaced to ensure operator safety.

14 Keep the work area neat. Lack of order will increasethe risk of accidents.

15 When working on the unit, wear safety clothing.Depending on the kind of activities these are: safetyglasses, ear protection, safety helmet (including visor),safety gloves, protective clothing, safety shoes. Do notwear the hair long and loose (protect long hair with ahairnet), or wear loose clothing or jewellery.

16 Take precautions against fire. Handle fuel, oil and anti-freeze with care because they are inflammablesubstances. Do not smoke or approach with nakedflame when handling such substances. Keep a fire-extinguisher in the vicinity.

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connections.If the compressor is to be used for sand-blasting or willbe connected to a common compressed-air system, fitan appropriate non-return valve (check valve) betweencompressor outlet and the connected sand-blasting orcompressed-air system. Observe the right mountingposition/direction.Before removing the oil filler plug, ensure that thepressure is released by opening an air outlet valve.Never remove a filler cap of the cooling water systemof a hot engine. Wait until the engine has sufficientlycooled down.Never refill fuel while the unit is running, unlessotherwise stated in the Atlas Copco Instruction Book(AIB). Keep fuel away from hot parts such as air outletpipes or the engine exhaust. Do not smoke whenfuelling. When fuelling from an automatic pump, anearthing cable should be connected to the unit todischarge static electricity. Never spill nor leave oil,fuel, coolant or cleansing agent in or around the unit.All doors shall be shut during operation so as not todisturb the cooling air flow inside the bodywork and/orrender the silencing less effective. A door should bekept open for a short period only e.g. for inspection oradjustment.Periodically carry out maintenance works according tothe maintenance schedule.Stationary housing guards are provided on all rotatingor reciprocating parts not otherwise protected andwhich may be hazardous to personnel. Machinery shallnever be put into operation, when such guards havebeen removed, before the guards are securelyreinstalled.Noise, even at reasonable levels, can cause irritationand disturbance which, over a long period of time, maycause severe injuries to the nervous system of humanbeings. When the sound pressure level, at any pointwhere personnel normally 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 continuously being present in theroom,

- below 85 dB(A): no action needs to be taken for occasionalvisitors staying a limited time only,

- above 85 dB(A): room to be classified as a noise-hazardous area and an obvious warning shall be placedpermanently at each entrance to alert people entering the

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5 Place the unit on level ground and apply the parkingbrake before disconnecting the unit from the towingvehicle. Unclip the safety break-away cable or safetychain. If the unit has no parking brake or jockey wheel,immobilize the unit by placing chocks in front of and/or behind the wheels. When the tow bar can bepositioned vertically, the locking device must beapplied and kept in good order. The unit must alwaysbe used/parked/stored in a non publicly accessible area,locked away from access by unauthorized persons.

6 To lift heavy parts, a hoist of ample capacity, tested andapproved according to local safety regulations, shall beused.

7 Lifting hooks, eyes, shackles, etc., shall never be bentand shall only have stress in line with their design loadaxis. The capacity of a lifting device diminishes whenthe lifting force is applied at an angle to its load axis.

8 For maximum safety and efficiency of the liftingapparatus all lifting members shall be applied as near toperpendicular as possible. If required, a lifting beamshall be applied between hoist and load.

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 not possible, thenecessary precautions must be taken to prevent load-swinging, e.g. by using two hoists, each atapproximately the same angle not exceeding 30° fromthe vertical.

11 Locate the unit away from walls. Take all precautionsto ensure that hot air exhausted from the engine anddriven machine cooling systems cannot berecirculated. If such hot air is taken in by the engine ordriven machine cooling fan, this may causeoverheating of the unit; if taken in for combustion, theengine 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 OPERATION1 When the unit has to operate in a fire-hazardous

environment, each engine exhaust has to be providedwith a spark arrestor to trap incendiary sparks.

2 The exhaust contains carbon monoxide which is alethal gas. When the unit is used in a confined space,conduct the engine exhaust to the outside atmosphereby a pipe of sufficient diameter; do this in such a waythat no extra back pressure is created for the engine. Ifnecessary, install an extractor. Observe any existinglocal regulations. Make sure that the unit has sufficientair intake for operation. If necessary, install extra airintake ducts.

3 When operating in a dust-laden atmosphere, place theunit so that dust is not carried towards it by the wind.Operation in clean surroundings considerably extendsthe intervals for cleaning the air intake filters and thecores of the coolers.

4 Close the compressor air outlet valve beforeconnecting or disconnecting a hose. Ascertain that ahose is fully depressurized before disconnecting it.Before blowing compressed air through a hose or airline, ensure that the open end is held securely, so that itcannot whip and cause injury.

5 The air line end connected to the outlet valve must besafeguarded with a safety cable, attached next to thevalve.

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. a waterseparator, a lubricator, etc. Do not step on the air outletvalves.

7 Never move a unit when external lines or hoses areconnected to the outlet valves, to avoid damage tovalves, 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 or death.For breathing air quality, the compressed air must beadequately purified according to local legislation andstandards. Breathing air must always be supplied atstable, suitable pressure.

9 Distribution pipework and air hoses must be of correctdiameter and suitable for the working pressure. Neveruse frayed, damaged or deteriorated hoses. Replacehoses and flexibles before the lifetime expires. Useonly the correct type and size of hose end fittings and

10

11

12

13

14

15

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TY DURING MAINTENANCE AND

IR

nance, overhaul and repair work shall only be out by adequately trained personnel; if required,supervision of someone qualified for the job. only the correct tools for maintenance and repair

rk, and only tools which are in good condition.ts shall only be replaced by genuine Atlas Copcolacement parts. maintenance work, other than routine attention,ll only be undertaken when the unit is stopped.ps shall be taken to prevent inadvertent starting. Inition, a warning sign bearing a legend such as

ork in progress; do not start” shall be attached to theting equipment. On engine-driven units the batteryll be disconnected and removed or the terminalsered by insulating caps. On electrically driven units main switch shall be locked in open position and fuses shall be taken out. A warning sign bearing aend such as ”work in progress; do not supplytage” shall be attached to the fuse box or maintch.ore dismantling any pressurized component, thepressor or equipment shall be effectively isolated

m all sources of pressure and the entire system shallrelieved of pressure. Do not rely on non-returnves (check valves) to isolate pressure systems. Inition, a warning sign bearing a legend such as

ork in progress; do not open” shall be attached toh of the outlet valves.or to stripping an engine or other machine orertaking major overhaul on it, prevent all movablets from rolling over or moving.ke sure that no tools, loose parts or rags are left inon the machine. Never leave rags or loose clothingr the engine air intake.ver use flammable solvents for cleaning (fire-risk).e safety precautions against toxic vapours of

aning liquids.ver use machine parts as a climbing aid.serve scrupulous cleanliness during maintenance repair. Keep away dirt, cover the parts and exposednings with a clean cloth, paper or tape.

ver weld on or perform any operation involving heatr the fuel or oil systems. Fuel and oil tanks must bepletely purged, e.g. by steam-cleaning, before

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room, for even relatively short times, about the need towear ear protectors,

- above 95 dB(A): the warning(s) at the entrance(s) shall becompleted with the recommendation that also occasionalvisitors shall wear ear protectors,

- above 105 dB(A): special ear protectors that are adequatefor this noise level and the spectral composition of thenoise shall be provided and a special warning to that effectshall be placed at each entrance.

18 The unit has parts, which may be accidentally touched,of which the temperature can be in excess of 176 °F (80°C) . The insulation or safety guard, protecting theseparts shall not be removed before the parts have cooleddown to room temperature. As it is technically notpossible to insulate all hot parts or to install safetyguards around hot parts (e.g. exhaust manifold, exhaustturbine), the operator / service engineer must always beaware not to touch hot parts when opening a machinedoor.

19 Never operate the unit in surroundings where there is apossibility of taking in flammable or toxic fumes.

20 If the working process produces fumes, dust orvibration hazards, etc., take the necessary steps toeliminate the risk of personal injury.

21 When using compressed air or inert gas to clean downequipment, do so with caution and use the appropriateprotection, at least safety glasses, for the operator aswell as for any bystander. Do not apply compressed airor inert gas to your skin or direct an air or gas stream atpeople. Never use it to clean dirt from your clothes.

22 When washing parts in or with a cleaning solvent,provide the required ventilation and use appropriateprotection such as a breathing filter, safety glasses,rubber apron and gloves, etc.

23 Safety shoes should be compulsory in any workshopand if there is a risk, however small, of falling objects,wearing of a safety helmet should be included.

24 If there is a risk of inhaling hazardous gases, fumes ordust, the respiratory organs must be protected anddepending on the nature of the hazard, so must the eyesand skin.

25 Remember that where there is visible dust, the finer,invisible particles will almost certainly be present too;but the fact that no dust can be seen is not a reliableindication that dangerous, invisible dust is not presentin the air.

26 Never operate the unit at pressures or speeds below orin excess of its limits as indicated in the technical

specifications.27 Do not use aerosol types of starting aids such as ether.

Such use could result in an explosion and personalinjury.

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OL APPLICATIONS SAFETY

ply the proper tool for each job. With the knowledge ofrrect tool use and knowing the limitations of tools,ng with some common sense, many accidents can bevented.ecial service tools are available for specific jobs andould be used when recommended. The use of thesels will save time and prevent damage to parts.

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carrying out such operations. Never weld on, or in anyway modify, pressure vessels. Disconnect thealternator cables during arc welding on the unit.

12 Support the tow bar and the axle(s) securely if workingunderneath the unit or when removing a wheel. Do notrely on jacks.

13 Do not remove any of, or tamper with, the sound-damping material. Keep the material free of dirt andliquids such as fuel, oil and cleansing agents. If anysound-damping material is damaged, replace it toprevent the sound pressure level from increasing.

14 Use only lubricating oils and greases recommended orapproved by Atlas Copco or the machine manufacturer.Ascertain that the selected lubricants comply with allapplicable safety regulations, especially with regard toexplosion or fire-risk and the possibility ofdecomposition or generation of hazardous gases.Never mix synthetic with mineral oil.

15 Protect the engine, alternator, air intake filter, electricaland regulating components, etc., to prevent moistureingress, e.g. when steam-cleaning.

16 When performing any operation involving heat, flamesor sparks on a machine, the surrounding componentsshall first be screened with non-flammable material.

17 Never use a light source with open flame for inspectingthe interior of a machine.

18 Disconnect –battery-clamp before starting electricalservicing or welding (evt. turn battery-switch in “off”position).

19 When repair has been completed, the machine shall bebarred over at least one revolution for reciprocatingmachines, several revolutions for rotary ones to ensurethat there is no mechanical interference within themachine or driver. Check the direction of rotation ofelectric motors when starting up the machine initiallyand after any alteration to the electrical connection(s)or switch gear, to check that the oil pump and the fanfunction properly.

20 Maintenance and repair work should be recorded in anoperator’s logbook for all machinery. Frequency andnature of repairs can reveal unsafe conditions.

21 When hot parts have to be handled, e.g. shrink fitting,special heat-resistant gloves shall be used and, ifrequired, other body protection shall be applied.

22 When using cartridge type breathing filter equipment,ascertain that the correct type of cartridge is used andthat its useful service life is not surpassed.

23 Make sure that oil, solvents and other substances likelyto pollute the environment are properly disposed of.

24 Before clearing the unit for use after maintenance oroverhaul, check that operating pressures, temperaturesand speeds are correct and that the control andshutdown devices function correctly.

TO

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t paint or coat the installed safety valve (see alsotive maintenance schedule).

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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, and which can causeburns if it contacts your skin. Therefore, be carefulwhen handling batteries, e.g. when checking the chargecondition.

2 Install a sign prohibiting fire, open flame and smokingat the post where batteries are being charged.

3 When batteries are being charged, an explosive gasmixture forms in the cells and might escape through thevent holes in the plugs. Thus an explosive atmospheremay form around the battery if ventilation is poor, andcan remain in and around the battery for several hoursafter it has 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 booster cables: connectthe + pole of AB to the + pole of CB, then connect the- pole of CB to the mass of the unit. Disconnect in thereverse order.

5 When using a starting aid, make sure the voltage doesnot exceed 30 VDC. A too high voltage can damage theelectronics.

Pressure vesselsMaintenance/installation requirements:1 The vessel can be used as pressure vessel or as

separator and is designed to hold compressed air for thefollowing 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 psi (bar),- the maximum working temperature Tmax in °F (°C),- the minimum working temperature Tmin in °F (°C),- the capacity of the vessel V in l (US gal, Imp gal, cu.ft).

2 The pressure vessel is only to be used for theapplications as specified above and in accordance withthe technical specifications. Safety reasons prohibitany other applications.

3 National legislation requirements with respect to re-inspection must be complied with.

4 No welding or heat treatment of any kind is permittedto those vessel walls which are exposed to pressure.

5 The vessel is provided and may only be used with therequired safety equipment such as manometer,overpressure control devices, safety valve, etc.

6 Draining of condensate shall be performed daily whenvessel is in use.

7 Installation, design and connections should not bechanged.

8 Bolts of cover and flanges may not be used for extrafixation.

9 (Pressure) vessel maintenance is to be performed byAtlas Copco.

Safety valvesOperating & MaintenanceOnly trained and technically competent personnel shouldconsider overhaul, re-set or performance testing of safetyvalves.The safety valve is supplied with either a lead securityseal or crimped cover to deter unauthorised access to thepressure 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 only correctparts supplied by Seetru and in accordance with theinstructions 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 to ensurefree and easy movement of internal parts.The frequency of tests is influenced by factors such as theseverity of the operating environment and aggressivenessof the pressurised medium.Soft seals and springs should be replaced as part of themaintenance procedure.

Do noPreven

erations. The bodywork is internally lined with sound-sorbing material.

ting beamlifting beam is accessible when a small door at the topopened.

ntrol panele control panel grouping the air pressure gauge, controlitch etc., is placed at the left hand/ rear end corner.

ta platee compressor is furnished with a data plate showing theduct code, the unit serial number and the workingssure .

haust systeme exhaust system includes a new exhaust aftertreatmenttem that meets strict installation standards and includes. a diesel particulate filter.

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Leading particulars

GENERAL DESCRIPTION

The XAS 1800 JD7 is a silenced, single-stage - twoelement in parallel, oil-injected screw compressor, builtfor a nominal effective working pressure of 100 - 150 psi(7 - 10 bar).The XAS 1800 CD7 is a silenced, single-stage - twoelement in parallel, oil-injected screw compressor, builtfor a nominal effective working pressure of 100 - 150 psi(7 - 10 bar).All machines meet Tier 4I / Stage IIIB emission standards.

EngineThe compressors are driven by a 6 cilinder in-line liquid-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 and lubricatingpurposes.

Compressor oil systemThe oil is boosted by air pressure. The system has no oilpump.The oil is removed from the air, in the air/oil vessel at firstby centrifugal force, secondly through the oil separatorelement.The vessel is provided with an oil level indicator.

RegulationThe compressor is provided with a continuous pneumaticregulating system and a blow-off valve which is integratedin the unloader assembly. The valve is closed duringoperation by air receiver pressure and opens by air

receiver pressure via the compressor element when thecompressor is stopped.When the air consumption increases, the air receiverpressure will decrease and vice versa.This receiver pressure variation is sensed by the regulatingvalve which, by means of control air to the unloader andan electronic engine speed regulator, matches the airoutput to the air consumption. The air receiver pressure ismaintained between the pre-selected working pressure andthe corresponding unloading pressure.

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 the engine.The cooling system is newly developped to dissipate theextra heat extracted from the exhaust during the cooledexhaust gas regeneration process.

Safety devicesA thermal shut-down sensor protects the compressoragainst overheating. The air receiver is provided with asafety valve.The engine is equipped with low oil pressure and highcoolant temperature shut-down sensors.The electric system is equipped with a 24V main switch.

Frame and axlesThe compressor/engine unit is supported by rubber buffersin a spillage-free frame.For available options see chapter Available options.

BodyworkThe bodywork has openings for the intake and outlet ofcooling air and hinged doors for maintenance and service

opab

LifA is

CoThsw

DaThpropre

ExThsysa.o

(F)

- 14 -

REGULATING SYSTEM

OVERVIEW

(TBV)

(CU)

(AR)

(WPG)

(PS)

(LV)

(RV)

(AOV)

(MPV)(OS)

(CU)

(F1)

(CBE) (SL)

(TV)

(OSV)

(CE)(TS)

(UA)

(C)(DP)

(E)

(DP)

(AFS)

(OC)(AFe)

(SC)

(AFce)

(SV)

(VV)

(BVof)(OFce)

(TS)

(TV)

(UA)

(CE)(DP)

(FPco)

(OLG)

(CV)

e injected oil, mixed with the compressed air, leaves thempressor element and re-enters the air receiver, where itseparated from the air as described in section Air flow. e oil that collects on the bottom of the oil separatorment is returned to the system through a scavenginge (SL), which is provided with a flow restrictor.e oil filter by-pass valve opens when the pressure droper the filter is above normal because of a clogged filter.e oil then by-passes the filter without being filtered. Fors reason, the oil filter must be replaced at regularervals (see section Preventive maintenance schedule).

- 15 -

AIR FLOWAir drawn through the airfilter (AFc) into the compressorelement (CElp CEhp) is compressed. At the elementoutlet, compressed air and oil pass into the air receiver/oilseparator (AR/OS).The check valve (CV) prevents blow-back of compressedair when the compressor is stopped. In the air receiver/oilseparator (AR/OS), most of the oil is removed from theair/oil mixture.The oil collects in the receiver and on the bottom of theseparator element.The air leaves the receiver via a minimum pressure valve(MPV) which prevents the receiver pressure fromdropping below the minimum working pressure, evenwhen the air outlet valves are open. This ensures adequateoil injection and prevents oil consumption. The minimumpressure valve (MPV) also functions as a check valve.The system comprises temperature sensors (TSlp, TShp),pressure sensors (PS) and a working pressure sensor(WPS).

OIL SYSTEMThe lower part of the air receiver (AR) serves as an oiltank.Air pressure forces the oil from the air receiver/oilseparator (AR/OS) through the oil cooler (OC), the oilfilters (OFc) 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) preventsthe oil from flowing back into the compressor element.The thermostatic by-pass valve (TBV) starts openingwhen the oil temperature is 150°F (70°C).The compressor element has an oil gallery in the bottom ofits casing. The oil for rotor lubrication, cooling and sealingis injected through holes in the gallery.Lubrication of the bearings is ensured by oil injected intothe bearing housings.

Thcois ThelelinThovThthiint

Reference NameAFce Air Filter (compr. element)AFe Air Filter (engine)AFS Air Filter SwitchAOV Air Outlet ValvesAR Air ReceiverBVof Bypass Valve oil filterC CouplingCBE Cubicle for Electrical devicesCE Compressor ElementCU Control UnitCV Check ValveDP Drain PlugE EngineF FanF1 FuseFPco Filler Plug (oil compressor element)LV Loading ValveMPV Minimum Pressure ValveOC Oil CoolerOFce Oil Filter (compressor element)OLG Oil Level GaugeOS Oil SeparatorOSV Oil Stop ValvePS Pressure SensorRV Regulating ValveSC Safety CartridgeSL Scavenge LineSV Safety ValveTBV Thermostatic Bypass ValveTS Temperature SensorTV Throttle ValveUA Unloader AssemblyVV Vacuator ValveWPG Working Pressure Gauge

(OC)

- 16 -

CONTINUOUS PNEUMATIC REGULATING SYSTEM

(TBV)

(AR)

(PS)

(RV)

(AOV)

(MPV)

(VH)

(OS)

(SL)

(TV)

(OSV)

(CE)(TS)

(UA)(BOV)

(AFce)

(BVof)(OFce)

(TS)

(TV)

(UA)

(CE)

(CV)

ep 4 Ash removalditives in lube oil that do not combust duringeneration, turn into ash. This reduces filter volume,

idation efficiency and backpressure.e ash must regularly be removed from the dieselrticulate filter. See service interval specified in thegine operating manual.

- 17 -

The compressor is provided with a continuous pneumaticregulating system and a blow-off valve (BOV) which isintegrated in the unloader assembly (UA). The valve isclosed during operation by outlet pressure of thecompressor element and opens by air receiver pressurewhen 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 unloader assembly(UA), matches the air output to the air consumption. Theair receiver pressure is maintained between the pre-selected working pressure and the correspondingunloading pressure.When starting the compressor, the throttle valve (TV) iskept closed via receiver pressure. The compressor element(CE) takes in air and pressure builds up in the receiver(AR). The throttle valve (TV) is closed. The air output iscontrolled from maximum output (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 the maximumair output, the engine speed is held at maximum load speedand the throttle valve (TV) is fully open.If the air consumption is less than the maximum air output,air receiver pressure increases and the regulating valvesupplies control air to throttle valve (TV) to reduce the airoutput and holds air receiver pressure between the normalworking pressure and the corresponding unloadingpressure. Unloading pressure = normal working pressure +14.5 psi (1 bar).When the air consumption is resumed, the blow off valve(BOV) closes and the throttle valve (TV) gradually opensthe air intake and the electronic speed regulator increasesthe engine speed.The construction of the regulating valve (RV) is such thatany increase (decrease) of the air receiver pressure abovethe pre-set valve opening pressure results in a proportionalincrease (decrease) of the control pressure to the throttlevalve and the electronic speed regulator.

Part of the control air is vented to atmosphere, and anycondensate discharged, through the vent holes (VH).

EXHAUST GAS AFTERTREATMENTTo meet the demands of EPA Tier4I / EU Stage IIIBEmission Legislation, the engine is equipped with anexhaust gas recirculation system and a particulate filter.The exhaust gas is fully automatically cleaned. Theprocess is monitored by the Xc4003 machine controller.

Step 1 Exhaust Gas Recirculation With Exhaust Gas Recirculation (EGR), part of theexhaust gases are cooled and then injected back into theengine cylinders to reduce NOx.Exhaust gas is cooled to allow the introduction of a greatermass of recirculated gas.The outcome is a lower peak combustion temperature.

Step 2 Diesel Particulate Filter + Diesel OxidationCatalystTo remove excess particulate matter from the exhaust gas,a Diesel Particulate Filter (DPF) is used. This systemconsists of a Diesel Oxidation Catalyst (DOC) and a filtermodule. The DOC reduces CO, HC and NO throughoxidation. It also produces NO2 to regenerate the DPF.The filter system removes 99% of particulate matter.

Step 3 Active regenerationParticulate matter left in the filter system is burned in aprocess called regeneration. Extending the.lifetime of afilter, it converts particulate matter into CO2 and ash. AtlasCopco engines use high temperature regeneration thatincludes a fuel burner in the exhaust stream thatintermittently raises the temperature above1100°F/600º C.Active regeneration decreases in the higher load cycles ofthe compressor.

StAdregoxThpaen

2

2

2

2

2

2

2

3

3

2

2

3

3

3

2

2

3

3

3

3

3

3

2

3

3

3

3

2,3

2,3

2

2

2

2

2

2

3

3

Description PageIndex John Deere 1Index Caterpiller 2Wiring Diagram Engine John Deere

3

Wiring Diagram Compressor John Deere

4

Wiring Diagram Engine Caterpiller

5

Wiring Diagram Compressor Caterpiller

6

Road Light System 7

- 18 -

ELECTRIC SYSTEM

CIRCUIT DIAGRAM INDEX - John DeereTag Description 1 Description 2 Location

F1 CIRCUIT BREAKER MAIN POWER BOX

F2 CIRCUIT BREAKER CHARGING ALTERNATOR POWER BOX

F3 CIRCUIT BREAKER ENGINE CONTROL MODULE POWER BOX

F4 CIRCUIT BREAKER DOSING PUMP POWER BOX

F5 CIRCUIT BREAKER TRANSFER PUMP POWER BOX

G1 BATTERY MACHINE

G2 BATTERY MACHINE

G3 CHARGIN ALTERNATOR ENGINE

H4 FLASHER LIGHT MACHINE

H6 HORN MACHINE

K0 START SOLENOID ENGINE

K1 START RELAY POWER BOX

LS1 LEVEL SWITCH COOLANT LEVEL WARNING MACHINE

LS2 LEVEL SWITCH COOLANT LEVEL SHUTDOWN MACHINE

LT1 LEVEL SENSOR FUEL LEVEL MACHINE

M1 STARTER MOTOR MACHINE

N1 CONNECTOR ENGINE CONTROL MODUL ENGINE

PS1 PRESSURE SWITCH AIRFILTER UNDERPRESSURE MACHINE

PS2 SWITCH EXTERNAL FUEL SUPPLY MACHINE

PT1 PRESSURE SENSOR VESSEL PRESSURE MACHINE

PT2 PRESSURE SENSOR REGULATING PRESSURE MACHINE

PT4 PRESSURE SENSOR OIL STOP VALVE # 1 PRESSURE MACHINE

PT5 PRESSURE SENSOR OIL STOP VALVE # 2PRESSURE MACHINE

R1 CONNECTOR CAN BUS TERMINATION W/120 OHM RESISTOR WIRING

S5 EMERGENCY STOP BUTTON MACHINE

TT1 PRESSURE SENSOR ELEMENT # 1 TEMPERATURE MACHINE


TT3 PRESSURE SENSOR AFTERCOOLER TEMPERATURE MACHINE

X1 CONNECTOR XC3003 PRIMARY CONTROL BOX

X2 CONNECTOR OPTION BOX WIRING

X3 CONNECTOR ENGINE CONTROL MODULE WIRING

X4 CONNECTOR ENGINE CONTROL AUXILIARY (12) POLE WIRING

X5 CONNECTOR JDEC DIAGNOSTIC WIRING

X6 CONNECTOR VARIABLE SPEED FAN DRIVE SENSOR WIRING

X7 CONNECTOR DPF TEMPREATURE SENSOR WIRING

X8 CONNECTOR DPF PRESSURE SENSOR WIRING

Y1 SOLENOID VALVE LOAD VALVE MACHINE

Y2 SOLENOID VALVE BLOW DOWN VALVE MACHINE

2

2

2

2

2

3

3

2

2

3

3

3

3

2

2

3

3

3

3

3

3

2

2

2

3

3

3

3

2,3

2,3

2

2

2

2

3

3

- 19 -

CIRCUIT DIAGRAM INDEX - Caterpiller

Tag Description 1 Description 2 Location

F1 CIRCUIT BREAKER MAIN POWER BOX

F2 CIRCUIT BREAKER CHARGING ALTERNATOR POWER BOX

F3 CIRCUIT BREAKER ENGINE CONTROL MODULE POWER BOX

G1 BATTERY MACHINE

G2 BATTERY MACHINE

G3 CHARGIN ALTERNATOR ENGINE

H4 FLASHER LIGHT MACHINE

H6 HORN MACHINE

K0 START SOLENOID ENGINE

K1 START RELAY POWER BOX

K2 CRS RELAY POWER BOX

LS1 LEVEL SWITCH COOLANT LEVEL WARNING MACHINE

LS2 LEVEL SWITCH COOLANT LEVEL SHUTDOWN MACHINE

LT1 LEVEL SENSOR FUEL LEVEL MACHINE

M1 STARTER MOTOR MACHINE

N1 CONNECTOR ENGINE CONTROL MODUL ENGINE

PS1 PRESSURE SWITCH AIRFILTER UNDERPRESSURE MACHINE

PS2 SWITCH EXTERNAL FUEL SUPPLY MACHINE

PT1 PRESSURE SENSOR VESSEL PRESSURE MACHINE

PT2 PRESSURE SENSOR REGULATING PRESSURE MACHINE



R1 CONNECTOR CAN A TERMINATION W/120 OHM RESISTOR WIRING



S5 EMERGENCY STOP BUTTON MACHINE



TT3 PRESSURE SENSOR AFTERCOOLER TEMPERATURE MACHINE

X1 CONNECTOR XC3003 PRIMARY CONTROL BOX

X2 CONNECTOR OPTION BOX WIRING

X3 CONNECTOR ENGINE CONTROL MODULE WIRING

X4 CONNECTOR ENGINE CONTROL AUXILIARY (12) POLE WIRING

X5 CONNECTOR DIAGNOSTIC CONNECOTR WIRING

X6 CONNECTOR AIR INLET TEMPERATURE SENSOR WIRING

Y1 SOLENOID VALVE LOAD VALVE MACHINE

Y2 SOLENOID VALVE BLOW DOWN VALVE MACHINE

- 20 -

WIRING DIAGRAM - ENGINE JOHN DEER - 320023-2

- 21 -

WIRING DIAGRAM - COMPRESSOR JOHN DEER - 320023 -3

- 22 -

WIRING DIAGRAM - ENGINE CATERPILLAR - 320031 -2

- 23 -

WIRING DIAGRAM - COMPRESSOR CATERPILLAR - 320031 -3

- 24 -

WIRING HARNESS - ROAD LIGHT - 317700

- 25 -

FUSE BOXCatReference NameF1 Main circuit breakerF2 Engine control moduleF3 CAT regeneration systemF4 Fuel priming pumpF13 Charging alternatorF14 Ignition Relay

John DeereReference NameF1 Main circuit breakerF2 Engine control moduleF3 Engine control moduleF13 Charging alternator

- 26 -

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.

80 psi(5.5 bar) Tyre pressure.

102 psi(7 bar) 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.

ABS braking system, emergency relay valve.

FTING INSTRUCTIONS

lift the compressor, use a lift truck or crane withficient capacity (weight: see indication on Disposal).e to it that the compressor will be lifted vertically and

ains level.

Lifting acceleration and retardation mustbe kept within safe limits (max. 2xg).Helicopter lifting is not allowed.Lifting is not allowed when the unit isrunning.When hoisting, the apex angle of thehoisting sling is not to exceed a maximum of60°.

- 27 -

Operating instructions

PARKING, TOWING AND LIFTING

INSTRUCTIONS

Safety precautions

Attention

PARKING INSTRUCTIONSWhen parking the compressor, lower tongue jack tosupport the compressor in a level position. Place thecompressor as level as possible; however, it can beoperated temporarily in an out-of-level position notexceeding 15°. If the compressor is parked on slopingground, immobilize the compressor by placing wheelchocks in front of or behind the wheels. Locate the rear-end of the compressor upwind, away from contaminatedwind-streams and walls. Do not obstruct air evacuation from the cooling system.Avoid recirculation of exhaust air from the engine. Thiscan cause overheating and engine power decrease.

The compressor oil lifetime will be shortened when thecompressor air inlet air is contaminated.

TOWING INSTRUCTIONSBefore towing the compressor, make sure the towingcapability and equipment of the tow vehicle is sufficient tosafety tow the compressor. When towing, the drawbar should be as level as possibleand the compressor and towing eye end in a level position.Raise tongue jack to the highest position. Attach safetychains/cables in a crisscross manner to the tow vehicle.This will help prevent the drawbar from contacting groundin event of a breakaway. If applicable, your compressor will be fitted with aemergency breakaway system, which is simply a smallbattery on your trailer and a switch connected to a cable.Secure the cable to your vehicle's trailer hitch. In case ofaccidental separation.

Locate the rear-end of the compressor upwind, away fromcontaminated wind-streams and walls. Do not obstruct airevacuation from the cooling system. Avoid recirculation of exhaust air from the engine. Thiscan cause overheating and engine power decrease.The compressor oil lifetime will be shortened when thecompressor air inlet air is contaminated.

LI

TosufSerem

The operator is expected to apply allrelevant Safety precautions.

Before putting the compressor into use,check the brake system.After the first 100 km travel:Check and retighten the wheel nuts andtowbar bolts to the specified torque. Seesection Torque values.

When the engine is running, the air outletvalves (ball valves) must always be put infully opened or fully closed position.

When towing, lifting or transporting thecompressor in any way, the battery switchmust always be in the “OFF” position!Also switch off the preheater as this unit isdirectly connected to the batteries.

ect fuel supply mode.

ternal supply. ove the lever of the fuel selection supply valve wards.

xternal supply. onnect the supply and return hose to the fuel nip-es at the fuel funnel. Move the lever of the fuel lection supply valve downwards.

C OPERATION OF THE MACHINEmpressor can be controlled in 4 different modes:

ocal Operation Mode: locally at the Operating nel,

emote Operation Mode: via remote switch inputs cated at the bottom of the Control panel, utomatic Operation Mode: via pressure sensor data om the customer's installation,

Operation Mode: with software running on a PC.

section is described how to operate the machine inOperation Mode at the Operation Panel.

Do not switch the fuel selecting lever whenthe unit is in operation!

- 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, up to the upper mark on the dipstick. Also check the engine coolant level. Consult the Engine Operation Manual for the type of coolant and type and viscosity grade of the engine oil.

4. Remove the air receiver drain plug (1), see figure, and open the valve to drain possible condensate. Close the valve when 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.Check that the battery switch is “ON”. The battery switch may only be switched off after the control unit has been switched off.

12.Attach the air line(s) to the closed air outlet valve(s). 13.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.

1. Sel

• InMup

• ECplse

BASIThe co• L

Pa• R

lo• A

fr• PC

In thisLocal

Before draining, ensure that the pressure isreleased.

Before removing oil filler plug (FP), ensurethat pressure is released by opening an airoutlet valve.

(1)

(2)

Make sure the unit is in a level position notexceeding 8° before refueling.

No external force may be applied to the airoutlet valve(s), e.g. by pulling hoses or byconnecting equipment directly to thevalve(s).

n a controlled way.

- 29 -

STARTING / STOPPING

Safety precautions

Make sure the fuel tank is filled up when “INTERNALFUEL” is selected.

BATTERY SWITCHThe compressor is equipped with a battery switch.When the compressor is not in use this switch must alwaysbe in the “OFF” position.It is not allowed to use this switch as an emergency switchor for stopping the compressor. It will cause damage in thecontrol unit when using this switch for stopping.Always first shut off the control unit and wait until thedisplay is dark before switching the battery switch toposition “OFF”.

CONTROL PANEL

Do not disconnect power supply to controlbox in any way when the control box isswitched on. This will cause memory loss.Do not switch off the circuit breaker whenthe control box is switched on. This willcause memory loss.

Please be aware that the (optional)preheater unit is still “live” with the batteryswitch in “OFF” position.

Reference NamePOWER OFF / ON switchTo switch the control panel on and off

START buttonPressing this button will start the compressor.

STOP buttonPressing this button will stop the compressor i

- 30 -

Reference NameLOAD button. Pressing this button will:• initiate the Auto Load function, or commands the compressor to load (depending on actual status).• command the compressor to switch to Not Loaded (when in Load).MEASUREMENTS VIEW buttonBy pressing this button you can toggle between Measurements View and Main View.

SETTINGS VIEW buttonBy pressing this button you can toggle between Settings View and Main View.

ALARMS VIEW buttonBy pressing this button you can toggle between Alarms View and Main View.

NAVIGATION buttonsThese buttons are used to navigate through the display menu’s.

ENTER buttonConfirms/stores the selection/change.

BACK buttonMoves back one level or ignores the change.

eference NameCompressor statusVessel pressure indication or info textCompressor infoMain View Indication

Measuring View Indication

Settings View Indication

Alarm View Indication

DPF REGENERATIONHigh Exhaust System Temperature.Means that the Diesel Particle Filter is being regenerated.DPF REGENERATIONDiesel Particle Filter Regeneration Forced.Means that Diesel Particle Filter will be regenerated as soon as all criteria to do so are met.DPF REGENERATIONDiesel Particle Filter Regeneration Inhibited.Means that the DPF regeneration is inhibited, even if all criteria to activate a regeneration are met.OVERHAULInitial Overhaul required.

OVERHAULMinor Overhaul required.

OVERHAULMajor Overhaul required.

AUTO LOADThis icon will be shown if the Auto Load functionality is enabled, or by means of a parameter setting, or by means of pressing the load button before the machine is ready to be loaded.PRESETDepending of which Pressure (and/or Flow) setting is active, the controller will show its dedicated icon.

- 31 -

OVERVIEW ICONS

MAIN VIEW

LOADED

1300RPM 22.4bar41% 1286h

1

2

3

0

R123

View

e Up and Down navigation buttons to scroll throughl list of settings. e Enter button to enter the selected submenu. e Back button to leave the entered (sub)menu.

View

e Up and Down navigation buttons to scroll throughl list of alarms. M Lists and the Log Lists can be selected and

d to access the sublist.

SETTINGS

LOADED

1300RPM 22.4bar41% 1286h

1000 GENERAL SETTINGS

2000 DIGITAL INPUTS

3000 VOLTAGE INPUTS

4000 TEMPERATURE INPUTS

5000 RELAY OUTPUTS

5300 SEMICONDUCTOR OUTPUTS

6000 SYSTEM SETTINGS

ALARMS

LOADED

1300RPM 22.4bar41% 1286h

3450 BATTERY LOW ALARM

2070 COOLANT LEVEL LOW

3010 FUEL LEVEL LOW

ECU DM1 LIST

ECU DM2 LIST

EVENT LOG LIST

ALARM LOG LIST

- 32 -

POSSIBLE VIEWS

Main View

Measuring View

Use the Up and Down navigation buttons to scroll throughthe full list of measurements.

Setup

Use ththe fulUse thUse th

Alarm

Use ththe fulThe Dentere

PRESETDepending of which Pressure (and/or Flow) setting is active, the controller will show its dedicated icon.OPERATION MODELocal

OPERATION MODERemote

OPERATION MODEPC Control

OPERATION MODEAutomatic

OPERATION MODEAutomatic Mode is active, but the Auto Start and Auto Stop function are both inactive.OPERATION MODEBlock Mode

ALARMActive & not-acknowledged Shutdown Alarm.ALARMActive & not-acknowledged Non-Shutdown Alarm.ALARMActive & acknowledged Alarm.

FUELTANKRunning at internal fueltank.

FUELTANKRunning at internal fueltank & Fuelpump is energized.FUELTANKRunning at external fueltank, but internal fueltank level is shown.FUELTANKRunning at external fueltank, but internal fueltank level is shown & fuelpump is energized.

MAIN VIEW

LOADED

1300RPM 22.4bar41% 1286h

22.4

MEASUREMENTS

LOADED

1300RPM 22.4bar41% 1286h

Running Hours 1286h

ECU Engine rpm 1300 rpm

ECU Requested Speed 1300 rpm

ECU DPF Soot Load 24 %

Vessel Pressure 22.4 bar

HP Element Temperature 101˚C

Ambient Temperature 27˚C

e display now shows

e machine is now ready to be started and is waiting fortart command.

ctive ButtonsStart Button(to initiate Start command)

Load Button(to activate Automatic Load)

Measurement View Button

Settings View Button

Alarms View Button

MAIN VIEW

PREPARING FOR START

0.0--RPM 0.0bar41% 1286h

- 33 -

STARTINGSwitch on the battery switch.Switch the controller on by switching the Power switch tothe position “ON”. The instrument panel will now perform a selftest; thefollowing display will be shown and the controller isinitialized:

During initializing all buttons/inputs/outputs/alarms areinactive.

This view will be shown for about 2 seconds, after whichthe display will show the Main View.

The actual vessel pressure is shown. If the measuredvessel pressure is higher than 21.8 psi (1.5 bar), the unitwill not start. The vessel pressure has to be lowered byopening the blow down valve. After power up, the vesselpressure normally is low enough to proceed with thestarting procedure.

Th

Tha s

Xc3003v1.00.0 (r7307)

If the Power switch is turned to the “OFF”position while the vessel is blowing down, itwill not power down for as long as the vesselpressure is higher than 1.5 bar.

Active ButtonsMeasurement View Button


Alarms View Button

MAIN VIEW

VESSEL BLOWING DOWN

3.91200RPM 3.9bar41% 1286h

A

e ButtonsStop Button(to cancel Start command)




Alarms View Button

MAIN VIEW

ENGINE PREHEATING

0.0--RPM 0.0bar41% 1286h

- 34 -

The display now shows

After pressing the START button the machine willactivate its horn and flasher light for 5 seconds, to notifythat it will start.

The display now shows

The engine electronics (ECU) will be powered up.As soon as communication between compressor controllerand engine controller is established, the machine willpreheat according to the parameters of the enginecontroller.

Active ButtonsStop Button(to cancel Start command)




Alarms View Button

MAIN VIEW

PREPARING FOR START

0.0--RPM 0.0bar41% 1286h

MAIN VIEW

READING ENGINE DATA

0.0--RPM 0.0bar41% 1286h

Activ

e engine starts running at idle speed. The display shows

e engine will run at minimum rpm, until the engine’solant temperature reaches 40°C, with a minimum time15 seconds and a maximum time of 300 seconds.

e display now shows

ctive ButtonsStop Button(to cancel Start command)




Alarms View Button

MAIN VIEW

ENGINE WARMING UP

1200RPM 3.3 bar41% 1286h

40˚C25˚C

13˚C

300s76s

0s

MAIN VIEW

ENGINE WARMING UP

1200RPM 2.9 bar41% 1286h

15s7s

0s

- 35 -

The engine starts crancking, the display shows

The engine cranks until 800 rpm is reached.If 800 rpm is not reached within 30 seconds, the startingprocedure is cancelled and the engine will rest for sometime. (Resting time depends on cranking time).

The display now shows Th

Thcoof

Th

800RPM324RPM

0RPM

MAIN VIEW

ENGINE CRANKING

324RPM 0.0bar41% 1286h





Alarms View Button

120s54s

0s

MAIN VIEW

ENGINE RESTING

--RPM 0.0bar41% 1286h

A

gine will now run at maximum rpm, the display will

ading valve will be energized and pressure startsg up.

e ButtonsStop Button(to cancel Start command)

Load Button(to cancel Load command)



Alarms View Button

MAIN VIEW

PREPARING TO LOAD

4.71800RPM 4.7bar41% 1286h

- 36 -

After warming up the machine is ready to be loaded and iswaiting for a load command; the display shows

Press the load button, the display will show

When the load button is pressed and the measured vesselpressure is lower then 65.2 psi (4.5 bar), the controller willrun a specific program to reach the requested 65.2 psi (4.5bar), in order to be able to load the machine. (Onlyapplicable for 2-stage machines).

The enshow

The lobuildinActive Buttons

Stop Button(to cancel Start command)

Load Button(to initiate Automatic Load)



Alarms View Button

MAIN VIEW

READY TO LOAD

4.61200RPM 4.6bar41% 1286h





Alarms View Button

MAIN VIEW

BUILDING UP VESSEL PRESSURE

3.91200RPM 3.9bar41% 1286h

Activ

- 37 -

During loading the following display is shown (defaultdisplay)

The controller controls the speed of the engine in order tomeet the requested working pressure, at the mosteconomical fuel usage.

DURING OPERATION

Regularly carry out following checks:1. Ensure 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.





Alarms View Button

MAIN VIEW

LOADED

18.61424RPM 18.6bar41% 1286h

The doors must be closed during operationand may be opened for short periods forinspection and adjustments only.

Be aware not to touch hot parts when thedoor is open.

When the engine is running, the air outletvalves (ball valves) must always be put in afully opened or fully closed position.

cooling down the engine will stop and the displayow

gine is stopped, and the controller will do a doubleto see if the engine is really stopped.

e ButtonsStart Button(to initiate Start command)



Alarms View Button

MAIN VIEW

ENGINE STOPPING

--RPM 5.3bar41% 1286h

- 38 -

STOPPINGAfter pressing the STOP button the display will show:

After a Stop command, or in case of a controlled stopalarm, the machine will cool down and run at minimumrpm for 3 minutes before it will stop.If the Soot Load in the diesel particulate filter is above30% when a stop command is given, the controller will askthe user if it is allowed to perform a complete DPFRegeneration cycle before stopping.

When ENTER is pressed the HEST icon will appear:

See paragraph DIESEL PARTICULATE FILTERREGENERATION.

After will sh

The encheck

A full DPF Regeneration can take up to anhour.

HEST Icon

MAIN VIEW

ENGINE COOLING DOWN

1200RPM 19.4bar41% 1286h

Press ENTER to allow DPF regen before stopDPF Soot Load level 50

180s1s

0s

Active ButtonsStart Button(to initiate Start command)



Alarms View Button

MAIN VIEW

ENGINE COOLING DOWN

1200RPM 6.0bar41% 1286h

180s84s

0s

Activ

ESEL PARTICULATE FILTER GENERATION

hen the Diesel Particle Filter regeneration process ispt at its default ‘AUTOMATIC’ setting, then the DPFeneration will be performed automatically when theot Load exceeds 60%.e controller display will indicate an ongoing DPFgeneration by showing the HEST icon (High Exhauststem Temperature):

e DPF regeneration process will continue, until the Sootad has become as low as possible, or until the engine ispped.hen the DPF regeneration process is stopped, the HESTn will disappear from the display.

HEST Icon

MAIN VIEW

LOADED

18.61424RPM 18.6bar41% 1286h

- 39 -

SHUTDOWNWhen the machine is shutdown due to a critical alarm oran emergency stop the display will show

POWER OFFSwitch the controller off by switching the Power switch tothe position “OFF”. 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 emergency switchor for stopping the compressor. It can damage the controller or the engine’s ElectronicControl Unit when using the battery switch for stopping.Always first shut off the controller and wait until thedisplay is dark before switching the battery switch toposition “OFF”.

DIREWkeregSoThReSy

ThLostoWico

Active ButtonsMeasurement View Button


Alarms View Button

Enter Button(to acknowledge the shown alarm)

MAIN VIEW

SHUTDOWN

0.02000 EMERGENCY STOP

EASING SOOT LOADthe DPF Regeneration is Inhibited, or when the does not get sufficient possibility to automaticallym a full DPF Regeneration, the Soot Load will the normal levels.ntroller will show the DPF Regeneration Needed

In case of Inhibited DPF Regeneration, the DPFeration Needed Icon will overwrite the DPFed Icon.

ed Action:rce DPF Regeneration, see paragraph FORCE

PF REGENERATIONDPF Regeneration is started, the DPF Regenerationd icon will disappear and the HEST icon will pop-

DPF Regeneration needed

MAIN VIEW

LOADED

18.61424RPM 18.6bar41% 1286h

- 40 -

AUTOMATIC DPF REGENERATION (DEFAULT)In specific cases, when the engine speed is constant atMinimum RPM, it can happen that the DPF regenerationalready starts from 30% Soot Load (LSR - Low SpeedRegeneration).This can happen in following situations:• Warming Up• Not Loaded• Loaded (when running in Unload condition - mini-

mum RPM)• CooldownWhen an LSR is ongoing while the soot load is less than60%, and the engine speed changes (engine is stopped,machine gets loaded, …), then the DPF Regenerationprocess will be stopped.If the Soot Load is higher than 30% when cooling downshould start (then an LSR is expected to be started) thecontroller will ask:

If Enter is pressed within 10 seconds then the controllerwill allow the DPF regeneration to be completed beforethe engine is stopped.

If Enter is not pressed (within 10 seconds), then the enginewill be stopped after cooling down.

INHIBIT DPF REGENERATIONWhen running in an environment where an elevatedexhaust temperature is not allowed, it might be necessaryto inhibit DPF regeneration. This has to be done at ServiceLevel. The controller has now put the DPF Regenerationin a FORCED OFF mode, which is Inhibit DPFRegeneration.The compressor controller will communicate with theengine controller and the (RED) Inhibit DPF regenerationicon will appear:

When the controller gets powered down, it will (at nextpower up) fall back to its default settings, meaningAUTOMATIC DPF regeneration.

INCRWhen engineperforexceedThe coIcon. RegenInhibit

Requir• Fo

DWhen Needeup.

A full DPF Regeneration can take up to anhour.

MAIN VIEW

ENGINE COOLING DOWN

1200RPM 19.4bar41% 1286h

Press ENTER to allow DPF regen before stopDPF Soot Load level 50

180s1s

0s

DPF Regeneration Inhibited

MAIN VIEW

READING ENGINE DATA

0.0--RPM 0.0bar41% 1286h

OT LOAD reaches 98%hen still no DPF regeneration is forced the next warningrm will pop-up.ditionally the machine will be prevented to Load:

quired Action:Acknowledge the ‘LOAD PREVENTION - HIGH DPF SOOT LOAD’ inhibit load alarm (press Enter while in the Main View).Force DPF Regeneration, see paragraph FORCE DPF REGENERATION

hen a DPF Regeneration is started, the DPFgeneration Needed icon will disappear and the HESTn will pop-up.


MAIN VIEW

LOADED

18.67110 LOAD PREVENTION - HIGH DPF SOOT LO...

- 41 -

SOOT LOAD reaches 85%When no DPF regeneration is forced a warning alarm willpop-up:

In case of Inhibited DPF Regeneration, the DPFRegeneration Needed Icon will appear.Required Action:• Acknowledge the ‘ECU DPF SOOT LOAD HIGH’

warning (press Enter while in the Main View).• Force DPF Regeneration, see paragraph FORCE

DPF REGENERATIONWhen DPF Regeneration is started, the DPF RegenerationNeeded icon will disappear and the HEST icon will pop-up.

SOOT LOAD reaches 90% (only when DPFRegeneration is Inhibited)When still no DPF regeneration is forced the next warningalarm will pop-up:

Required Action:• Acknowledge the ‘PLEASE FORCE DPF REGEN-

ERATION !’ warning (press Enter while in the Main View).

• Force DPF Regeneration, see paragraph FORCE DPF REGENERATION

When DPF Regeneration is started, the DPF RegenerationNeeded icon will disappear and the HEST icon will pop-up.

SOWalaAd

Re•

•

WReico


MAIN VIEW

LOADED

18.67100 ECU DPF SOOT LOAD HIGH


MAIN VIEW

LOADED

18.67130 PLEASE FORCE DPF REGENERATION !

INGSttons to be used see “Control Panel”

owledge an Alarmlarm becomes active, for example a Low Fuel Levelng:

his alarm can be acknowledged by pressing theR button. If the fuel level is still low, the view will to:

n as the fuel level is higher than the warning level,rm icon will automatically disappear.g as there is an alarm icon in the middle of the part of the view, all active acknowledged / un-ledged alarms can be seen by pressing the

M VIEW buttong the ALARM VIEW button again, will bring you

o the Main View.

MAIN VIEW

LOADED

12.33000 FUEL LEVEL LOW WARNING

MAIN VIEW

LOADED

12.31300RPM 12.3bar9% 1381h

- 42 -

SOOT LOAD reaches 101%If still no action is taken the following warning appearsand the controller will perform a controlled shutdown.

As soon as the engine is stopped, the DPF RegenerationNeeded icon will disappear (engine electronics arepowered down)..

FORCE DPF REGENERATION

If DPF Regeneration is Inhibited

Machine is not running:Power the controller down. At next power up, the DPFRegeneration settings will be back to default, and anAutomatic DPF Regeneration will take place at thesoonest appropriate moment.

Machine is running:• Press the Settings View Button• Enter the ‘1000 GENERAL SETTINGS’ menu• Scroll one line down and Enter the ‘1140 ECU DPF

REGENERATION’ menuOR • Scroll down and Enter the ‘MODE’ parameter• Scroll down and Enter the ‘AUTOMATIC’ setting• Press the Back button 3 times to get back to the Main

ViewDPF Regeneration setting will now be AUTOMATICDPF REGENERATION.Customer Level can now select between AUTORegeneration & INHIBIT Regeneration, as long as thecontroller is not powered down (after power down, it willfall back to its default DPF Regeneration settings, and aService Level is needed to go back to Inhibit DPFRegeneration).

SETTFor bu

AcknIf an aWarni

then tENTEchange

As soothe alaAs lonbottomacknowALARPressinback t

Contact Atlas Copco for further actions tobe taken.

MAIN VIEW

SHUTDOWN

18.67120 SOOT LOAD TOO HIGH - CALL ATLAS CO...

ENTER the ‘FUNCTION’ menu, scroll to AUTO LOAD settingpress ENTER.

w the AutoLoad function is active, and as soon as theit is Ready To Start, the display will show the Autoad icon.w press BACK until you’re back in the Main View (orthe menu you require).

- 43 -

Set ClockPress the SETTINGS VIEW button• scroll to ‘1000 GENERAL SETTINGS’• press ENTER• scroll to ‘1290 DATE/TIME’ • ENTER the Date/Time menu• scroll to the parameter you want to change• ENTER this parameter.To change the ‘RTC Month’, scroll to the preferred monthand press ENTER.To change any other RTC setting, the red figure iseditable. Scroll up/down and press ENTER to change. Use left/rightto shift between editable figures.Now press BACK until you’re back in the Main View (orin the menu you require).

Set LanguagePress the SETTINGS VIEW button.• scroll to ‘1000 GENERAL SETTINGS’• press ENTER• scroll to ‘1300 LANGUAGES’ • ENTER the LANGUAGES menu, • ENTER the ‘SETTINGS’ parameter• scroll to the preferred language• press ENTER.Now press BACK until you’re back in the Main View (orin the menu you require).

Set UnitsPress the SETTINGS VIEW button, • scroll to ‘1000 GENERAL SETTINGS’ • press ENTER • scroll to the unit you would like to change:

‘1340 TEMPERATURE UNITS’‘1350 PRESSURE UNITS’‘1360 FUEL FLOW UNITS’‘1370 AIR FLOW UNITS’

• ENTER the preferred menu• ENTER the ‘SETTINGS’ parameter

• scroll to the preferred setting• press ENTER.Now press BACK until you’re back in the Main View (orin the menu you require).

Change Display SettingsPress the SETTINGS VIEW button• scroll to ‘1000 GENERAL SETTINGS’• press ENTER• scroll to ‘1310 DISPLAY BACKLIGHT’• ENTER the DISPLAY BACKLIGHT menu• scroll to the setting you would like to change• press ENTER.To change a setting, the red figure is editable.Scroll up/down and press ENTER to change. Use left/rightto shift between editable figure.Now press BACK until you’re back in the Main View (orin the menu you require).

Go To DiagnosticsPress the SETTINGS VIEW button• scroll to ‘1000 GENERAL SETTINGS’• press ENTER• scroll to ‘1150 DIAGNOSTICS’ • ENTER the Diagnostics menu, • ENTER the ‘ENABLE’ parameter• scroll to ‘ON’ and press ENTER.Now the ECU will get PAC (ignition) and one can performECU diagnostics (read DM1 List, DM2 List, ECU values,perform engine diagnostics, …).Now press BACK until you’re back in the Main View (orin the menu you require).To leave Diagnostics, press the STOP button.

Set the AutoLoad FunctionPress the SETTINGS VIEW button• scroll to ‘1000 GENERAL SETTINGS’• press ENTER• scroll to ‘1160 AUTO LOAD’

•••NounLoNoin

l box.

Failclass TriggerWarning XcWarning XcWarning XcWarning XcWarning XcWarning XcWarning Xc

Inhibit Load XcWarning XcWarning Xc

Shutdown XcShutdown XcWarning Xc

Shutdown XcWarning XcWarning XcWarning Xc

Controlled Stop XcWarning Xc

Controlled Stop XcShutdown XcShutdown XcShutdown XcWarning Xc

Shutdown XcIndication XcWarning Xc

Shutdown XcControlled Stop Xc

Warning XcWarning Xc

Controlled Stop XcShutdown XcShutdown XcWarning XcWarning Xc

Controlled Stop XcWarning XcWarning Xc

- 44 -

FAULT CODESThere are several parameters that are continuously watched.When one of these parameters exceeds its specified limit the compressor will react depending the present status of the contro

Alarmcode Alarmtext1231 FUEL FILL CHECK1503 INITIAL OVERHAUL REQUIRED1522 MINOR OVERHAUL WITHIN ** H1523 MINOR OVERHAUL WITHIN ** D1524 MINOR OVERHAUL REQUIRED1552 MAJOR OVERHAUL WITHIN ** H1553 MAJOR OVERHAUL WITHIN ** D1554 LOAD PREVENTION - FIRE RISK1558 COMP. OIL CHANGE WITHIN ** H1559 COMP. OIL CHANGE WITHIN ** D2000 EMERGENCY STOP INPUT2040 REMOTE EMERGENCY STOP2070 COOLANT LEVEL LOW WARNING2080 COOLANT LEVEL LOW SHUTDOWN2090 P AIRFILTERS HIGH2100 NO PROJECTFILE DOWNLOADED3000 FUEL LEVEL LOW WARNING3010 FUEL LEVEL LOW SHUTDOWN3020 FUEL LEVEL SENSOR CIRCUIT3050 VESSEL PRESSURE HIGH WARNING3060 VESSEL PRESSURE HIGH SHUTDOWN3070 VESSEL PRESSURE SENSOR CIRCUIT3120 REGULATING PRESSURE SENSOR CIRCUIT3170 AIR DISCHARGE PRESSURE SENSOR CIRCUIT3320 INLET PRESSURE SENSOR CIRCUIT3450 BATTERY LOW ALARM3460 BATTERY HIGH ALARM3660 FIRE RISK - CHECK OILSTOPVALVE3680 OSV PRESSURE SENSOR CIRCUIT3720 INTERSTAGE PRESSURE SENSOR CIRCUIT4000 L.P. ELEMENT TEMPERATURE HIGH4010 L.P. ELEMENT TEMP. ALARM 24020 L.P. ELEMENT TEMP. ALARM 34040 L.P. ELEMENT TEMP. SENSOR CIRCUIT4070 AMBIENT TEMPERATURE SENSOR CIRCUIT 4100 AIR DISCHARGE TEMPERATURE ALARM 14110 AIR DISCHARGE TEMPERATURE ALARM 24120 A.D. TEMPERATURE SENSOR CIRCUIT4150 H.P. ELEMENT TEMPERATURE ALARM 1

U - FUEL TEMPERATUREU - OIL TEMPERATUREU - ENGINE SPEEDU - INJECTOR 1U - INJECTOR 2U - INJECTOR 3U - INJECTOR 4U - INJECTOR 5U - INJECTOR 6U - INJECTOR 7U - INJECTOR 8U - SOOT LOAD

Controlled Stop XcShutdown XcShutdown XcWarning Xc

Indication XcShutdown XcIndication XcShutdown XcShutdown XcIndication XcShutdown XcShutdown XcShutdown XcShutdown XcShutdown ECUWarning ECUWarning ECU

Shutdown XcShutdown Xc

Controlled Stop XcControlled Stop Xc

Warning XcInhibit Load Xc

Controlled Stop XcWarning Xc

Failclass Trigger

- 45 -

Details of ECU triggered alarms can be monitored via the ECU DM1 LIST menu

In case of ECU AMBER LAMP or ECU PROTECT LAMP:Only possible when engine is running or if Diagnostics Mode is active.Access the ECU DM1 LIST menu via Alarm View.

In case of ECU RED LAMP:Do NOT acknowledge the ECU RED LAMP alarm.DM1 alarms are automatically copied into the Alarm View, and can be read there.

For all ECU triggered alarms, the respective SPN code is shown in the ECU DM1 LISTA full list of supported SPN codes is provided by the engine manufacturer.

For following alarms, the Xc controller also shows full text next to the SPN code:

ECU - FUEL FILTER PRESSUREECU - INTERCOOLER TEMPERATUREECU - FUEL PRESSUREECU - FUEL FILTER PRESSUREECU - WATER IN FUELECU - OIL LEVELECU - OIL FILTER PRESSUREECU - OIL PRESSUREECU - TURBO BOOST PRESSUREECU - TURBO OIL PRESSUREECU - INTAKE MANIFOLD TEMPERATUREECU - AIR INLET PRESSUREECU - COOLANT TEMPERATUREECU - COOLANT LEVELECU - SUPPLY VOLTAGEECU - AMBIENT AIR TEMPERATUREECU - AIR INLET TEMPERATURE

ECECECECECECECECECECECEC

4160 H.P. ELEMENT TEMPERATURE ALARM 24170 H.P. ELEMENT TEMPERATURE ALARM 34190 H.P. ELEMENT TEMP. SENSOR CIRCUIT4220 AFTERCOOLER AIR TEMP SENSOR CIRCUIT4230 AFTERCOOLER FREEZING DANGER5200 AIR SHUT OFF6190 CHARGE MONITORING FAIL6327 START FAILURE6329 STARTER SPEED TOO LOW6388 VESSEL PRESSURE TOO LOW TO LOAD6426 UNINTENTIONAL RUN6427 RUN FAILURE6428 STOP FAILURE7002 ECU COMMUNICATION7007 ECU RED LAMP7008 ECU AMBER LAMP7009 ECU PROTECT LAMP7010 ECU ENGINE SPEED TOO LOW7020 ECU ENGINE SPEED ALARM 27030 ECU ENGINE COOLANT TEMP. ALARM7050 ECU ENGINE AIR INLET TEMP. ALARM 17100 ECU DPF SOOT LOAD HIGH7110 PLEASE FORCE DPF REGENERATION !7120 LOAD PREVENTION - HIGH DPF SOOT LOAD7130 SOOT LOAD TOO HIGH - CALL ATLAS COPCO

Alarmcode Alarmtext

- 46 -

EMERGENCY STOP

When an emergency stop button (1) is pressed, power toall outputs is terminated, by the emergency stop itself(hardware) as well as by the software.When the emergency stop button (1) is pressed theoperator can unlock the emergency stop by turning itcounterclockwise.

The emergency stop button is only to be usedin emergency situations; not for stoppingprocedures.

(1)

FETY PRECAUTIONS

Before performing any maintenance jobsalways put the battery switch in the “OFF”position. See section Battery switch.Always observe the applicable safetyprecautions. See section Safety duringmaintenance and repair.Please note that when the battery switch isoff there can still be some parts live!

Unauthorised modifications can lead to riskfor injury or machine damage.

Always keep the machine tidy in order toprevent fire hazard.

Poor maintenance can void any warrantyclaims.

- 47 -

Maintenance

LIABILITY

The manufacturer does not accept any liability for anydamage arising from the use of non-original parts and formodifications, additions or conversions made without themanufacturer’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 and after1000 running hours.It guarantees that all necessary parts are replaced at thesame 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 for normalmaintenance 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 specific repairor rebuilding task.It guarantees that all necessary parts are replaced at thesame 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 to operate theunloading and regulating components. Close the air outletvalves after stopping.

SA

Contact Atlas Copco.

If the compressor is going to be storedwithout running from time to time,protective measures must be taken.

very 0 hrs

Every 1000 hrs

Every 2000 hrs

Yearly

fits of genuine parts, save on administration costs and its.

x x xx x xx x xx x xx x xx x

- 48 -

PREVENTIVE MAINTENANCE

SCHEDULE

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 a guideline forunits operating in a dusty environment typical forcompressor applications. Maintenance schedule can beadapted depending on application, environment andquality of maintenance.

MAINTENANCE SCHEDULE COMPRESSOR

To determine the maintenance intervals, use of service hours, or calendar time, whichever occurs first.Service hours Daily 50 hrs

after initial start-up

Every 250 hrs

Every 500 hrs

E75

For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the beneare offered at a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the service kDrain water from fuel filter xDrain condensate and water from spillage-free frame or catch basin (10) xEmpty air filter vacuator valves xCheck engine oil level (if necessary top up) xCheck compressor oil level (if necessary top up) xCheck coolant level xCheck/Fill fuel level (3) xCheck function of coolant heater (option) xCheck control panel xCheck on abnormal noise xCheck electrical system cables for wear xCheck for leaks in engine-, compressor-, air-, oil-, or fuel system x xCheck torque on critical bolt connections xCheck electrolyte level and terminals of battery x xCheck engine (minimum and maximum) speed x xReplace compressor oil filter(s) (5) xInspect/Adjust fan belt x x(to be continued on page 49)

Every 750 hrs

Every 1000 hrs

Every 2000 hrs

Yearly

xx xx xx xx x xx x xx x xx x xx x xx x xx x xx xx xx x

x x xx x xx x xx x xx x xx x xx x xx x xx x xx x xx x xx x xx x xx x x

x xx xx

- 49 -

Maintenance schedule (hrs)(continuation of page 48)

Daily 50 hrs after initial start-up

Every 250 hrs

Every 500 hrs

Obtain engine oil sample (2) (12) xDrain/Clean fuel tank water and sediments (1) xReplace fan belt xHoses and clamps - Inspect/Replace xChange engine oil (2) xReplace engine oil filter (2) xReplace fuel (pre)filters (6) xClean flow restrictor in oil scavenge line xClean oil cooler(s) (1) xClean radiator (1) xClean intercooler (1) xInspect starter motor xInspect turbocharger xInspect waterpump xCheck engine protective devices xCheck functioning of regulating valveTest safety valve (9)Replace bleed-off valve unloaderCheck rubber flexibles (11)Clean after cooler (option) (1)Replace DD/PD/QD filter (option)Clean oil stop valveChange compressor oil (1) (7)Replace oil separator elementClean fuel coolerClean crankcase breather filter and check for obstructionsReplace air filter element (1)Check external fuel connection (option)Inspection by Atlas Copco service technicianAdjust engine inlet and outlet valves (2)Inspect alternatorReplace spring check valve(to be continued on page 50)

very 50 hrs

Every 1000 hrs

Every 2000 hrs

Yearly

xxxxx

the bolts of the housing, the lifting eye, the towbarhe axle securely tightened. to section Technical specifications for the torques.

- 50 -

Notes

Maintenance schedule (hrs)(continuation of page 49)

Daily 50 hrs after initial start-up

Every 250 hrs

Every 500 hrs

E7

Replace crankcase breather filterGrease hingesCheck emergency stopAnalyse coolant (4) (8)Check/Replace safety cartridgeCheck/Clean diesel particulate filter (2)(to be continued on page 51)

1. More frequently when operating in a dusty environment.2. Refer to engine operation manual.3. After a day’s work.4. Yearly is only valid when using PARCOOL. Change coolant every 5 years.5. Use Atlas Copco oil filters, with by-pass valve as specified in the parts list.6. Gummed or clogged filters means fuel starvation and reduced engine performance.7. See section Oil specifications.8. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing

points:• 2913 0028 00 : refractometer• 2913 0029 00 : pH meter.9. See section Safety valve.10.See section Before starting.11.Replace all rubber flexibles every 6 years.

For other specific engine and alternator requirements refer to specific manuals.12.Samples to be obtained/analysed every 500 hours, starting at 250 hours. (250, 750, 1250,...)

Keepand tRefervalue

very 000 km

Every 2000 km

Yearly

x x

x xx xx xx xx xx xx xx xx xx xx xx xx x

xx

- 51 -

Maintenance schedule (km)(continuation of page 50)

Daily 50 km after initial start-up

Every 500 km

E1

Check coupling head xDrain ABS vessel (option) xCheck tyre pressure x x xCheck height of adjusting facility x x xCheck torque of wheel nuts xGrease coupling head, towbar bearings at the housing of the overrun brake xCheck brake system (if installed) and adjust if necessary xOil or grease brake lever and moving parts such as bolts and joints xCheck/Adjust lateral play of wheel bearing (conventional bearing) xCheck tyres for uneven wearGrease sliding points on height adjusting partsCheck safety cable for damageCheck bowden cable on height adjustable connection device for damageLubricate torsion bar axle trailing armCheck hub cap for firm seatingCheck brake lining wearChange wheel hub bearing grease

- 52 -

OIL SPECIFICATIONS

High-quality, mineral, hydraulic or synthesizedhydrocarbon oil with rust and oxidation inhibitors anti-foam and anti-wear properties is recommended.The viscosity grade should correspond to the ambienttemperature and ISO 3448.

PAROIL from Atlas Copco is the ONLY oil tested andapproved for use in all engines built into Atlas Copcocompressors and generators.Extensive laboratory and field endurance tests on AtlasCopco equipment have proven PAROIL to match alllubrication demands in varied conditions. It meetsstringent quality control specifications to ensure yourequipment will run smoothly and reliably.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, high chemicalstability and rust- inhibiting additives help reduce

corrosion, even within engines left idle for extendedperiods.PAROIL contains high quality anti-oxidants to controldeposits, sludge and contaminants that tend to build upunder very high temperatures. PAROIL's detergentadditives keep sludge forming particles in a finesuspension, instead of allowing them to clog your filterand accumulate in the valve/rocker cover area.PAROIL releases excess heat efficiently, whilstmaintaining excellent bore-polish protection to limit oilconsumption.PAROIL has an excellent Total Base Number (TBN)retention and more alkalinity to control acid formation.PAROIL prevents Soot build-up.PAROIL is optimized for the latest low emission EURO -3 & -2, EPA TIER II & III engines running on low sulphurdiesel for lower oil and fuel consumption.PAROIL E xtra is a Synthetic ultra high performancediesel engine oil with a high viscosity- index. Atlas CopcoPAROIL E xtra is designed to provide excellentlubrication from start-up at temperatures as low as -13°F(-25°C).PAROIL E Mission Green is a mineral based highperformance diesel engine oil with a high viscosity- index.Atlas Copco PAROIL E Mission Green is designed toprovide a high level of performance and protection under'standard' ambient conditions from -14°F (10°C) onward.PAROIL E xtra and PAROIL E Mission Green are lowSAPS oil. These oils are to be used in Tier 4I / Stage IIIBengines in order to provide the full performance and life ofthe engine and aftertreatment systems.

It is strongly recommended to use Atlas Copcobranded lubrication oils for both compressorand engine.

Only use synthetic compressor oil.

Never mix synthetic with mineral oil.Remark:When changing from mineral to synthetic oil(or the other way around), you will need to doan extra rinse:After a complete change over to synthetic oil,run the unit for a few minutes to allow properand complete circulation of the synthetic oil.Then drain the synthetic oil again and fill againwith new synthetic oil. To set correct oil levels,follow the normal instructions.

US gal Order number1.3 1630 0160 005.3 1630 0161 00

55.2 1630 0162 00264 1630 0163 00

S gal Order number5.3 1630 0180 00

55.2 1630 0181 00264 1630 0182 00

Order number1630 0135 001630 0136 00

Order number1630 0471 001630 0472 001630 0473 00

- 53 -

COMPRESSOR OIL

Choose your compressor oil based on the ambienttemperatures in the actual operating area.

ENGINE OIL

Choose your engine oil based on the ambient temperaturesin the actual operating area.

50˚ C

40˚ C

-40˚ C

-30˚ C

-10˚ C

-20˚ C

-0˚ C

10˚ C

20˚ C

30˚ C

122˚ F

104˚ F

86˚ F

68˚ F

50˚ F

-40˚ F

-22˚ F

32˚ F

14˚ F

-4˚ F

PAR

OIL

S x

trem

e

PAR

OIL

S x

trem

e

PAR

OIL

S

PAR

OIL

S

50˚ C

40˚ C

-40˚ C

-30˚ C

-10˚ C

-20˚ C

-0˚ C

10˚ C

20˚ C

30˚ C

122˚ F

104˚ F

86˚ F

68˚ F

50˚ F

-40˚ F

-22˚ F

32˚ F

14˚ F

-4˚ F

PAR

OIL

E x

tra

PAR

OIL

E M

ISS

ION

GR

EE

N

PAR

OIL

E x

tra

PAR

OIL

E M

ISS

ION

GR

EE

N

Synthetic compressor oil PAROIL S

Mineral compressor oil PAROIL S xtreme

Synthetic engine oil PAROIL E xtra

Mineral engine oil PAROIL E Mission Green

Litercan 5can 20barrel 210container 1000

Liter Ucan 20barrel 210container 1000

Liter US galcan 5 1.3can 20 5.3

Liter US galcan 5 1.3can 20 5.3barrel 210 55.2

ND OIL FILTER CHANGE

NE OIL AND OIL FILTER CHANGEction Preventive maintenance schedule.

ING UP THE COMPRESSOR OIL

p the compressor. Wait a few minutes until the ssure is released through the automatic blow-down e. Make sure that all pressure is released by

sening the filler plug (1) one turn.it a few minutes until the oil level is constant.

ove the filler plug (1) and top up with oil until the nter of the oil level gauge (2) is in the upper part of green area.nstall and tighten the filler plug (1).

(1)

(2)

- 54 -

OIL LEVEL CHECK

CHECK ENGINE OIL LEVELAlso consult the Engine Operation Manual for the oilspecifications, viscosity recommendations and oil changeintervals.For intervals, see Preventive maintenance schedule.Check engine oil level in accordance with the instructionsin the Engine Operation Manual and if necessary, top upwith oil.

CHECK COMPRESSOR OIL LEVEL

With the compressor off and standing horizontal, checkthe level of the compressor oil.The pointer of the oil level gauge (1) must register in theupper extremity of the green range. Add oil if necessary.

DIESEL FUEL RECOMMENDATIONS

Misfueling with fuels of higher sulfur level canhave the following negative effects:• Shorten the time interval between aftertreatment

device service intervals (cause the need for more fre-quent service intervals).

• Adversely impact the performance and life of after-treatment devices (cause loss of performance).

• Reduce regeneration intervals of aftertreatment devices.

• Reduce engine efficiency and durability.• Increase the wear.• Increase the corrosion.• Increase the deposits.• Lower fuel economy.• Shorten the time period between oil drain intervals

(more frequent oil drain intervals).• Increase overall operating costs.• Failures that result from the use of improper fuels

will not be covered by warranty.

OIL A

ENGISee se

TOPP

1. Stoprevalvloo

2. Wa3. Rem

poithe

4. Rei

Before removing the oil filler plug (2), ensurethat the pressure is released by opening an airoutlet valve (3).

(1)

(2)

(3)

Ultra Low Sulfur Diesel (ULSD) fuel 0.0015percent (15 ppm (mg/kg)) sulfur is requiredby regulation for use in engines certified byregulation for use in engines certified tononroad Tier 4 standards (U.S. EPA Tier 4certified) and that are equipped with exhaustaftertreatment systems.

- 55 -

COMPRESSOR OIL AND OIL FILTER CHANGE

The quality and the temperature of the oil determine the oilchange interval.The prescribed interval is based on normal operatingconditions and an oil temperature of up to 212 °F (100 °C)(see section Preventive maintenance schedule).When operating in high ambient temperatures, in verydusty or high humidity conditions, it is recommended tochange the oil more frequently.

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) by a single 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. Unscrew the filler plug (2) to speed up draining. After draining, reposition and tighten the drain plugs (4).

3. Remove the oil filters (1), e.g. by means of a special tool. Catch the oil in a drain pan.

4. Clean the filter seat on the manifold, taking care that no dirt drops into the system. Oil the gasket of the new filter element. Screw it into place until the gasket 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.

In this case, contact Atlas Copco.

(1)(2)

(3)

(4)

Never add more oil. Overfilling results in oilconsumption.

Vessel cover contaminated

clean

Vessel contaminated

clean

rval, draining is sufficient

PAROIL Sxtremedraining

draining *

- 56 -

COMPRESSOR OIL FLUSHING

PROCEDURE

To avoid problems when changing over to a new type ofoil (see table) a special Compressor Oil FlushingProcedure has to be followed. The table is only valid whenthe replaced oil has not exceeded its lifetime. For moreinformation consult Atlas Copco Service dept.Aged oil can be recognized best by using an oil samplinganalysis program. Indicators for aged oil are strong smell,or contamination such as sludge and varnish inside the oilvessel and oil stop valve or a brownish colour of the oil.Whenever aged oil is discovered, eg. when changing theoil separator, contact Atlas Copco Service dept. to haveyour compressor cleaned and flushed.1. First thoroughly drain the system when the oil is warm,

leaving as little oil in the system as possible, especially in dead areas, if possible blow out remaining oil by pressurising the oil system. Check the instruction manual for detailed description.

2. Remove the compressor oil filter(s).3. Open the oil vessel and remove the oil separator

element.

4. Check the interior of the oil vessel (see pictures). If varnish deposits are discovered, contact Atlas Copco Service dept. and do not continue.

5. Put in a new oil separator, screw on new compressor oil filter(s) and close the oil vessel according to the instructions.

6. Fill the oil vessel with the minimum amount of replacement oil, run the compressor under light load conditions for 30 minutes.

7. Thoroughly drain the system when the oil is warm, leaving as little oil in the system as possible, especially in dead areas, if possible blow out remaining oil by pressurising the oil.

8. Fill the system with the final oil charge.9. Run the compressor under light load conditions for 15

minutes and check for leakage. 10.Check the oil level and top up if necessary.11.Collect all waste lubricant used during the flushing

process and dispose of it in accordance with the applicable procedures for managing waste lubricant.

Not respecting compressor oil changingintervals in accordance with the maintenanceschedule, can lead to serious problems,including fire hazard! The manufacturer doesnot accept any liability for damage arisingfrom not following the maintenance scheduleor not using genuine parts.

Instructions on replacing the oil separatorelement are available from Atlas CopcoService dept.

*When changing over to the same oil within the oil changing inte

PAROIL SPAROIL S draining *PAROIL Sxtreme draining

cause PARCOOL EG inhibits corrosion, depositmation is minimized. This effectively eliminates flowtriction problems through the engine coolant ducts and radiator, minimizing the risk of engine overheating andssible failure.educes water pump seal wear and has excellent stabilityen subjected to sustained high operating temperatures.RCOOL EG is free of nitride and amines to protect

ur health and the environment. Longer service lifeuces the amount of coolant produced and disposaluirements, which limits environmental impact.

n of deposits, the concentration of the additives in theturer's guidelines. Topping up the coolant with water

nt mixture.

gal Order number1604 5308 001604 5307 011604 5306 00

gal Order number1604 8159 00

- 57 -

COOLANT SPECIFICATIONS

The use of the correct coolant is important for proper heattransfer and protection of liquid-cooled engines. Coolantsused in these engines must be mixtures of good qualitywater (distilled or de-ionised), special coolant additivesand anti-freeze, if required. Coolant that is not tomanufacturer's specification will result in mechanicaldamage of the engine.The freezing point of the coolant must be lower than thefreezing point that can occur in the area. The differencemust be at least 9 °F (5 °C). If the coolant freezes, it maycrack the cylinder block, radiator or coolant pump.Consult the engine's operation manual and follow themanufacturer's directions.

PARCOOL EG

PARCOOL EG is the only coolant that has been testedand approved by all manufacturers of enginescurrently used in Atlas Copco compressors andgenerators.Atlas Copco's PARCOOL EG extended life coolant is thenew range of organic coolants purpose-designed to meetthe needs of modern engines. PARCOOL EG can helpprevent leaks caused by corrosion. PARCOOL EG is alsofully compatible with all sealants and gasket typesdeveloped to join different materials used within anengine.PARCOOL EG is a ready to use Ethylene Glycol basedcoolant, premixed in an optimum 50/50 dilution ratio, forantifreeze protection guaranteed to -40°F (-40°C).

BeforresthepoIt rwhPAyoredreq

Never remove the cooling system filler capwhile coolant is hot.The system may be under pressure. Removethe cap slowly and only when coolant is atambient temperature. A sudden release ofpressure from a heated cooling system canresult in personal injury from the splash of hotcoolant.

It is strongly recommended to use Atlas Copcobranded coolant.

Never mix different coolants and mix thecoolant components outside the coolingsystem.

PARCOOL EG

To ensure protection against corrosion, cavitation and formatiocoolant must be kept to certain limits, as stated by the manufaconly, changes the concentration and is therefore notallowed.Liquid-cooled engines are factory-filled with this type of coolaPARCOOL EG Concentrate

Liter US can 5 1.3can 20 5.3barrel 210 55.2

Liter UScan 5 1.3

refractometer can be ordered from Atlas Copco ith part number 2913 0028 00.

ING UP/REPLACING COOLANTerify whether the engine cooling system is in a od condition (no leaks, clean,...).

heck the condition of the coolant. the condition of the coolant is no longer up to stan-rd, the complete coolant should be replaced (see ction Replacing the coolant).lways top-up with PARCOOL EG Concentrate / RCOOL EG.pping up the coolant with water only, changes the ncentration of additives and is therefore not lowed.

In case of a mix of different coolant productsthis type of measuring might provideincorrect values.

- 58 -

HANDLING PARCOOL EGPARCOOL EG should be stored at ambient temperatures,while periods of exposure to temperatures above 95 °F (35°C) should be minimized. PARCOOL EG can be storedfor a minimum of 5 years in unopened containers withoutany effect on the product quality of performance.PARCOOL EG is compatible with most other coolantsbased on ethylene glycol, but you only get the benefits of5 years protection when its used on its own. Exclusive useof PARCOOL EG is recommended for optimum corrosionprotection and sludge 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 to measureEG, no PG can be measured afterwards as a result of thedifference in the density. More specific measurements canbe done by the use of a refractometer. This device canmeasure both EG and PG. A mix of both products will beshow unreliable results!Mixed EG coolants with identical glycol type can bemeasured by use of a refractometer as well as the ‘density’system. The mixed coolants will be considered as oneproduct.The use of distilled water is recommended. If you haveexceptionally soft water it would be acceptable, as well.Basically, the engine metals are going to corrode to someextent no matter what water you use, and hard water willencourage the resulting metal salts to precipitate.PARCOOL EG comes as a pre-mixed coolant to safeguardthe quality of the complete product.It is recommended that topping up of the cooling system isalways done with PARCOOL EG.

COOLANT CHECK

In order to guarantee the lifetime and quality of theproduct, thus optimising engine protection, regularcoolant-condition-analysis is recommended.The quality of the product can be determined by threeparameters:

Visual check• Verify the appearance of the coolant with regard to

its colour and make sure that no loose particles are floating around.

pH measurement• Check the pH value of the coolant using a pH-mea-

suring 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 always be above 33 vol.%.

• Mixtures exceeding a 68 vol.% mix ratio in water are not recommended, as this will lead to high engine operating temperatures.

• Aw

TOPP• V

go• C• If

dase

• APA

• Tocoal

Never remove the cooling system filler capwhile coolant is hot.The system may be under pressure. Removethe cap slowly and only when coolant is atambient temperature. A sudden release ofpressure from a heated cooling system canresult in personal injury from the splash of hotcoolant.

- 59 -

TOPPING UP WITHOUT DRAINING FROM THE COOLING SYSTEMThe 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=

In case of expansion tank at low level, this quantityis to be filled without draining from the coolingsystem.

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 815900

be estimated with the following formula and/or graph:

- 60 -

TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEMThe quantity of PARCOOL EG Concentrate to be topped up after draining a calculated volume from the cooling system, canCorrections 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=

In case of expansion tank at normal level, thisquantity is to be drained from the coolingsystem.

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 815900

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 with drainage

Top

-up

volu

me

(lite

r)

- 61 -

REPLACING THE COOLANT

Drain• Completely drain the entire cooling system.• Used coolant must be disposed of or recycled in

accordance with legislation and local regulations.

Flush• Flush twice with clean water. Used coolant must be

disposed or recycled in accordance with laws and local regulations.

• Using 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 proper cleaning reduces contamination risks.

• In case of "other" coolant residues inside 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 tem-perature 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 coolingefficiency.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 agent maybe applied (do not use jet at max. power).

Close the service door(s).

Caution: do not top up when the engine is hot.

Remove any dirt from the coolers with a fibrebrush. Never use a wire brush or metalobjects.

To avoid damaging the coolers, angle betweenjet and coolers should be approx. 90 °.

Protect the electrical and controllingequipment, air filters, etc. against penetrationof moisture.Never leave spilled liquids such as fuel, oil,coolant and cleansing agents in or around thecompressor.

(1)

(2)

(3)

(4)

PRESSOR ELEMENT OVERHAUL

a compressor element is due for overhaul, it needsdone by Atlas Copco. This guarantees the use ofe parts and correct tools with care and precision.

- 62 -

BATTERY CARE

If the battery is still dry, it must be activated as describedin section Activating a dry-charged battery.The battery must be in operation within 2 months frombeing activated; if not, it needs to be recharged first.

ELECTROLYTE

Electrolyte in batteries is a sulphuric acid solution indistilled water.The solution must be made up before being introducedinto the battery.

Activating a dry-charged battery• Take out the battery.• Battery and electrolyte must be at an equal tempera-

ture above 50 °F (10 °C).• Remove cover and/or plug from each cell.• Fill each cell with electrolyte until the level reaches

10 mm (0.4 in) to 15 mm (0.6 in) above the plates, or to the level marked on the battery.

• Rock the battery a few times so that possible air bub-bles 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 BATTERYBefore and after charging a battery, always check theelectrolyte level in each cell; if required, top up with

distilled water only. When charging batteries, each cellmust be open, i.e. plugs and/or cover removed.

Preferably use the slow charging method and adjust thecharge current according to the following rule of thumb:battery capacity in Ah divided by 20 gives safe chargingcurrent in Amp.

Make-up distilled waterThe amount of water evaporating from batteries is largelydependant on the operating conditions, i.e. temperatures,number of starts, running time between start and stop,etc...If a battery starts to need excessive make-up water, thispoints to overcharging. Most common causes are hightemperatures or a too high voltage regulator setting.If a battery does not need any make-up water at all over aconsiderable time of operation, an undercharged batterycondition may be caused by poor cable connections or atoo low voltage regulator setting.

PERIODIC BATTERY SERVICE• Keep the battery clean and dry.• Keep the electrolyte level at 10 to 15 mm above the

plates or at the indicated level; top up with distilled water only. Never overfill, as this will cause poor performance and excessive corrosion.

• Record the quantity of distilled water added.• Keep the terminals and clamps tight, clean, and

lightely covered in petroleum jelly.• Carry out periodic condition tests. Test intervals of 1

to 3 months, depending on climate and operating conditions, are recommended.

• If doubtful conditions are noticed or malfunctions arise, keep in mind that the cause may be in the elec-tical system, e.g.loose terminals, voltage regulator maladjusted, poor performance of compressor, etc...

COM

When to be genuin

Before handling batteries, read the relevantsafety precautions and act accordingly.

Read the safety instructions carefully.

Use a commercial automatic battery chargerin accordance with the manufacturer’sinstructions.

PLACING THE FILTER ELEMENT AND THE FETY CARTRIDGE

e instructions apply to one air filter and should beeated for both air filters engine and air filters

mpressor.Release the snap clips (1) and remove the dust trap cover (2). Clean the inside of the cover.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 mal-functioning filter element.

Reassemble in reverse order of dismantling.Inspect and tighten all air intake connections.

Replace the filter element and the safetycartridge at the same time. New elementsshould be inspected for tears and puncturesbefore installation.

The safety cartridge cannot be cleaned.

(1)(2)

(3)

(4)

(5)

- 63 -

ADJUSTMENTS AND SERVICING

PROCEDURES

ADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM

The working pressure is determined by the tension of thespring in the regulating valve (1). This tension can beincreased to raise the pressure and decreased by turningthe adjusting wheel clockwise and anti-clockwiserespectively.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 (2) closed, adjust the regulating

valve (1), until a pressure is reached of nominal pressure + 29 psi (+ 2 bar).

4. Lock the regulating valve (1) by fixing the lock nut.

AIR FILTERS ENGINE / COMPRESSOR

MAIN PARTS

CLEANING THE DUST TRAPTo remove dust from the dust trap squeeze the vacuatorvalve (6) several times.

RESA

Threpco1.

2.

3.4.

Be aware not to touch hot parts when the dooris open.

(1)

(2)

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 of non-original air filters may lead to severe damageof the engine and/or compressor element.

(6) (1)(2) (3) (4) (5)

- 64 -

Air receiver

The air receiver (1) is tested according to officialstandards. Carry out regular inspections in conformitywith 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.

• An annual check of the set pressure according to local regulations. This check cannot be done on the machine and must be carried out on a proper test bench.

Daily drain condensate.

(2)

(1)

All adjustments or repairs are to be done by anauthorized representative of the safety valve(2) supplier, see section Specific safetyprecautions.

EANING CRANKCASE BREATHER FILTER

After switching off the engine, let it cool down for about 30 minutes.Open the clasps (2) and carefully separate the bowl from the head. Be aware that hose (3) is still attached.Take out the wire mesh and clean it in a solvent (diesel fuel).Thoroughly dry the wire mesh with compressed air.Put the wire mesh in the bowl and mount the bowl to the head. Do not twist hose (3).

(2)

(1) (1)

(3)

- 65 -

FUEL SYSTEM

PRIMING INSTRUCTIONS

Prime the fuel system in order to fill the fuel filter. Primethe fuel system in order to purge trapped air. The fuelsystem should be primed under the following conditions:• Compressor is put in operation for the first time• Running out of fuel• Storage• Replacement of the fuel filter

Key-on priming (if equipped)

1. Turn the diagnostics mode to the ON position. Leave the diagnostics mode in the ON position for 2 minutes.

2. Verify that the water separator is full of fuel.3. If the water separator is not full of fuel, turn the

diagnostics mode OFF and then turn the diagnostics mode ON. Turning the switch OFF, then ON will cycle the fuel priming pump again.

4. When the water separator is full of fuel, attempt to start the engine. If the engine starts and the engine runs rough or the engine misfires, operate at low idle until the engine is running smoothly. If the engine cannot be started, or if the engine continues to misfire or smoke, repeat Step 1.

Manual switch priming (if equipped)The manual switch is located on the primary filter base/electric priming pump assembly.1. Hold the manual switch in the up position until fuel has

filled the water separator.2. Continue to hold the switch for 30 seconds after the

water separator is full.3. Attempt to start the engine. If engine starts and runs

rough or misfires, operate at low idle until the engine is running smoothly. If the engine cannot be started, continue to prime the fuel system for 30 more seconds.

REPLACING FILTER ELEMENTS

Replacing the filter elements:

Installation instructions:1. Drain fuel from the bowl.2. Remove filter (3) 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 (3) tightly by hand.7. Check for leaks, retighten if necessary.

CL

1.

2.

3.

4.5.

Fuel leaked or spilled onto hot surfaces orelectrical components can cause a fire. To helpprevent possible injury, turn the “ON/OFF”switch in position “OFF” when changing fuelfilters or water separator elements. Clean upfuel spills immediately.

Do not loosen the fuel lines at the fuelmanifold. The fittings may be damaged and/ora loss of priming pressure may occur when thefuel lines are loosened.

Do not allow dirt to enter the fuel system.Thoroughly clean the area around a fuelsystem component that will be disconnected.Fit a suitable cover over disconnected fuelsystem component.

(1)

(2)

(3)

ING LUBRICATION with bearing adjustment, proper lubrication isial to the current function and reliability of youraxle. Bearing should be lubricated every 12 months00 miles. Repack bearings as follows:e a quantity of grease into the palm of your hand.s a section of the widest end of the bearing into thedge of the grease pile closet to the thumb forcing

into the interior of the bearing.eat this while rotating the bearing from roller to

tinue this process until you have the entire bearingetely filled with grease.ore installing, apply a light coat of grease on theg cup.

ING LUBRICATION—OILr axles are equipped with oil lubricated hubs, thenubrication procedure is to periodically fill the hub high quality hypoid gear oil to the level indicated onar plastic oil cap. l can be filled through the rubber plug hole in theecommended Oil—SAE 90 Hypoid Gear (Hypoidxle Oil)

INSPECTION AND REPLACEMENTver the hub is removed, it’s recommended to

e the seals to assure that the seal properly seals theg cavity. To replace the seal: the seal out of the hub with a screwdriver. Neverhe seal out with the inner bearing as you may causee to the bearing.ly Permatex sealant to the outside of the new seal. the new seal into place using a clean wood block.

- 66 -

RUBBER TORSION SUSPENSIONThe RUBBER TORSION suspension system is a torsionarm type suspension, which is completely self-containedwithin the axle tube. It attaches directly to the trailer frameusing brackets, which are an integral part of the axleassembly. The RUBBER TORSION axle provides improvedsuspension characteristics relative to leaf spring axlesthrough the unique arrangement of a steel torsion barsurrounded by four natural rubber cords incased in themain structural member of the axle beam. The wheel/ hub spindle is attached to a lever, called thetorsion arm, which is fastened to the rubber-encased bar. As the load applied, the bar rotates causing a rolling/compressive resistance in the rubber cords. This actionprovides the same functions as conventional sprung axleswith operating advantages including independentsuspension.

INSPECTIONAll the components of your suspension system should bevisually inspected at least every 6,000 miles for signs ofexcess ware, elongation of bolt holes, and loosening offasteners. Whenever loose or replaced, the fasteners in yoursuspension system should be torqued as in the chart below

BRAKE DRUM INSPECTIONThere are two areas of the brake drum that are subject towear and require periodic inspection. These two areas are the drum surface where the brakeshoes make contact during stopping and the armaturesurface where the magnets contacts (only on electricbrakes.) The drum surface should be inspected for excessive wearor heavy scoring. If worn more than .020” oversized, orthe drum has worn out of round more than .015”, then thedrum surface should be turned. If scoring or other wear is greater than .090” on thediameter, the drum must be replaced.

When turning the drum surface, the maximum re-borediameter for a 12 1/4” brake drum is 12.340”. Themachined inner surface of the brake drum that contacts theBrake magnet is called the armature surface. If the armature surface is scored or worn unevenly, itshould be refaced to a 120 micro inch finish by removingnot more than .030” of material.To insure proper contact between the magnet armatureface and the drum surface should be refaced whenever themagnets are replaced.

BEARING INSPECTIONWash all grease and oil from the bearing cone using asuitable solvent. Dry the bearing with clean, lint free clothand inspect the rollers completely. If any pitting, spalling, or corrosion is present, thenreplace the bearing. The bearing cup inside the hub mustbe inspected also. ALWAYS REPLACE THE BEARINGS AND CUP INSETS.When replacing the bearing cup proceed as follows:1. Place the hub on a flat work surface with the cup to bereplaced on the bottom side.2. Using a brass drift punch, carefully tap around the smalldiameter end of the cup to drive it out.3. After cleaning the hub bore area, replace the cup bytapping in with the brass drift punch. Be sure the cup isseated all the way up against the retaining shoulder in thehub.Replace only with bearing as specified in theaccompanying Bearing Replacement Chart.

BEARAlongessenttrailer or 12,01. Plac2. Presouter egrease3. Reproller.4. Concompl5. Befbearin

BEARIf youyour lwith athe cleThe oicap. RRear A

SEALWhenereplacbearin1. Prydrive tdamag2. App3. Tap

It’s important to have wheel-bearing boresfree of metallic chips and contamination. Make sure all cavities are free ofcontamination before reinstalling the bearingand seals.

- 67 -

BEARING ADJUSTMENT AND HUB REPLACEMENTIf the hub has been removed or bearing adjustment isrequired, the following adjustment procedure must befollowed:1. Install the bearing and washer into the hub. Thread onthe inner nut, rotate the hub and tighten the nut to 100 Ft-Lbs. of torque.2. Then loosen the spindle nut to remove the torque. Donot rotate the hub.3. Finger tighten the spindle nut until snug.4. Back the spindle nut off slightly 1/4 to 3/8 turn.5. Place the tang washer on the spindle and bend two tangsinward over the nut. This will keep the inner nut fromturning while torque is applied to the outer nut6. Install the outer nut and torque it to 100—175 Ft-Lbs.Insure that the inner nut does not turn. Bend two tangsfrom the tang washer over the outer nut flats to secure.7. Install cap with the O-ring and plug installed. Rotate thehub and check the bearing adjustment. The allowable endplay is .001” - .010”.

y.

opco Service representative.

e leading to unloader. If air leaks from the hose, remove and

rvice representative.

ring seat. Withdraw the valve and inspect. Replace parts rt and 2 long setscrews: first remove the short screws, then

ion.

- 68 -

Problem solving

It is assumed that the engine is in good condition and thatthere is adequate fuel flow to the filter and injectionequipment.

Make sure that the wires are not damaged and that they areclamped tight to their terminals.For denomination of switches, relays, etc., see ELECTRICSYSTEM.

See also section Control panel.An electrical fault must be traced by anelectrician.

Problem: Compressor capacity or pressure below normal.

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 necessar

Regulating valve (RV) defective. Have regulating valve removed and inspected by an Atlas C

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 hosinspect loading valve. Replace damaged or worn O-rings.

Oil separator element clogged. Have element removed and inspected by an Atlas Copco Se

Air intake throttle valve remains partially closed. Remove air filters, air intake manifold and throttle valve spwhere necessary. Caution: the spring seat is fixed with 4 shorelease the spring tension unscrewing the long ones.

Safety valve (SV) leaking. Remove and inspect. Replace if not airtight after reinstallat

Blow-off valve leaking. Remove and inspect. Replace if necessary.

as Copco Service representative.

g hoses.

spring seat. Withdraw the valve and inspect. Replace ith 4 short and 2 long setscrews: first remove the short

ong ones.

ilter elements and safety cartridges. Check the oil level inutes, stop and recheck oil level.

ilter elements and safety cartridges. Check the oil level inutes, stop and recheck oil level.

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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.


Regulating valve (RV) opens too late or its ball valve spring is broken. Have regulating valve removed and inspected by an Atl

Air leaks in regulating system. Check hoses and their fittings. Stop leaks; replace leakin

Air intake throttle valve does not close for some reason. Remove air filters, air intake manifold and throttle valveparts where necessary. Caution: the spring seat is fixed wscrews, then release the spring tension unscrewing the l

Minimum pressure valve malfunctioning. Remove and inspect valve.

Blow-off valve malfunctioning. Remove and inspect valve.


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.


Check valve at element outlet. Remove and inspect. Replace if necessary. Replace air fand add oil if necessary. Run the compressor for a few m

Plunger of oil stop valve jammed. Remove and inspect. Replace if necessary. Replace air fand add oil if necessary. Run the compressor for a few m

e polarity and connect the batteries correctly.

with other compressors, leave space between them.

cessary.

sing. Replace if out of order.

opco Service representative.

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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 th4. Never operate the engine without the main or voltage sensing cables connected in the circuit.


Insufficient compressor cooling. Locate compressor away from walls; when banked

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 ne

Thermostatic by-pass valve remains stuck in opened position. Remove valve and check for proper opening and clo

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 C

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Available options

FORK LIFT SLOTS

With fork lift slots the compressor can easily be movedwith a fork lift truck on building sites where it isimpossible to use a towing truck.

AFTER-COOLER

An integral after-cooler, with water separator (1), isavailable to reduce the outlet air temperature and cut watercontent. This performance can be obtained under optimalatmospheric conditions.When an after-cooler is used in an application where thetemperature is critical the air outlet temperature can bemonitored by the compressor controller. A warning can be set at a value between 0°C and 115°C(=default value) and a shut-down can be set at a valuebetween 0°C and 120°C (= default value). The operatorhas authority to modify these values so the process can beguarded and kept in a safe condition under allcircumstances. See also table Fault codes on page page 44.The installation includes a by-pass over the after-cooler.For applications that demand quality air, a fine filtrationunit (2) can be specified with the after-cooler package.This will remove oil and particles down to 0.01 mg/m3.

Ensure forklift capability is sufficient to liftmachine weight.

Torque value (Nm / lbf.ft)

270 (200)+10/-0 %205 (152)+/- 10 %205 (152)+/- 10 %

46 (34)+/- 10 %80 (60)+/- 10 %205 (152)+/- 10 %80 (60)+/- 10 %

205 (152)+/- 10 %46 (34)+/- 10 %23 (17)+/- 10 %

125 (93)+/- 10 %205 (152)+/- 10 %205 (152)+/- 10 %205 (152)+/- 10 %

es 12 (9)+/- 10 %

ank cap of the fuel tank handtight.

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Technical specifications

TORQUE VALUES

GENERAL TORQUE VALUESThe following tables list the recommended torques applied for general applicationsduring 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 8 (6)+/-25 %M8 20 (15)+/-25 %M10 41 (30)+/-25 %M12 73 (54)+/-25 %M14 115 (85)+/-25 %M16 185 (137)+/-25 %

Thread size Torque value (Nm / lbf.ft) M6 14 (10)+/-21 %M8 34 (25)+/-23 %M10 70 (52)+/-24 %M12 120 (89)+/-25 %M14 195 (144)+/-23 %M16 315 (233)+/-23 %

AssembliesAxles to frame:Wheel nutsBolts, front axle/frameBolts, rear axle/frameCompressor to frame:Bolts, elements/gear casingBolts, elements/supportBolts, support/bufferBolts, buffer/frameEngine to frame:Bolts, engine/supportBolts, support/bufferBolts, buffer/frameLifting beams to frame:Bolts, lifting beams/yoke (M12)Bolts, lifting beams/yoke (M16)Bolts, lifting beams/A-FramesBolts, A-Frames/frameHose clamps:Pebra hose clamps on all IC/radiator hos

Secure the drain cock and t

S 1800 CD7 XAS 1800 JD75 14.5

106820

-150 100-1500 7-10

S 1800 CD7 XAS 1800 JD7584175121224814-10-13-25

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COMPRESSOR / ENGINE SPECIFICATIONS

REFERENCE CONDITIONS

The inlet conditions are specified at the air inlet grating outside the canopy.

LIMITATIONS

Designation XA

Absolute inlet pressurepsi 14.bar(e) 1

Relative air humidity % 0

Air inlet temperature°F 68°C 20

Nominal effective working pressurepsi 100bar(e) 7-1

Designation XA

Minimum effective receiver pressurepsi 58bar(e) 4

Maximum effective receiver pressure, compressor unloadedpsi 175bar(e) 12

Maximum abmient temperature at sea level with aftercooler

°F 122°C 48

Minimum starting temperature°F 14°C -10

Minimum starting temperature, with coldstart equipment°F -13°C -25

S 1800 CD7 XAS 1800 JD70 21000 13000 1800.5 849.5

S 1800 CD7 XAS 1800 JD76 10-06 <1.6 10-06

<34.0

.0 113.0

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PERFORMANCE DATA

At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.

1) Free air delivery is measured according to ISO 1217 ed.3 1996 annex D

Designation XAEngine shaft speed, normal and maximum r/min 195Engine shaft speed, compressor unloaded r/min 120

Free air delivery (FAD) 1) With aftercooler cfm 180l/s 849

Fuel consumption- at 100% FAD Fuel expert kg/h

No aftercooler lb/hAftercooler kg/hNo Fuel expert lb/h

- at 75% FAD Fuel expert kg/hNo aftercooler lb/hAftercooler kg/hNo Fuel expert lb/h



- at unload Fuel expert kg/hNo aftercooler lb/hAftercooler kg/hNo Fuel expert lb/h

Designation XA

Typical oil content of compressed airgram/cu.ft <1.mg/m3 <3

Engine oil consumption (maximum)oz/h 4.0g/h 113

<76

104

- 75 -

ALTITUDE UNIT PERFORMANCE CURVEMax. allowable working pressure as a function altitude and ambient temperature.

Noise level- Sound pressure level (LP), complies with ISO 2151 under free field conditions at 7 m distance dB(A) <76- Sound power level (LW) complies with 2000/14/EC dB(A)- Sound power level (LW) complies with 84/533/EEC and 85/406/EEC limits dB(A) 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 to following national standards: British BSI 1571 part 1German DIN 1945 Part 1Swedish SS-ISO 1217American ANSI PTC9

14 32 50 68 86 104 122

-10 0 10 20 30 40 50

ALT

ITU

DE

m

ALT

ITU

DE

ft

TEMPERATURE °F

TEMPERATURE °C

US gal 25 25l 95 95US gal 236 236l 908 908US gal 300 300l 1135 1135US gal 557 557l 2108 2108

Tandem Wagon Skidin 234.8 199.5 181.5mm 5963.9 5067.3 4610.1in 89.4 89.4 89.4mm 2270.8 2270.8 2270.8in 101.8 101.3 90.9mm 2585.7 2573.0 2308.9

XAS 1800 CD7

XAS 1800 JD7

- 76 -

DESIGN DATA

Compressor

Engine

(1) - Time at full load not to exceed 50% of the duty cycle or 1 hour max.(2) - Continuous per ISO 3046

Compressor Dimensions

DesignationNumber of compression stages 1 (TWIN)

Designation XAS 1800 CD7

XAS 1800 JD7

Make Caterpillar John DeereType C15

PQ-94506135HFC95

Coolant Liquid LiquidNumber of cylinders 6 6

Borein 5.39 5.2mm 137 132

Strokein 6.73 6.5mm 171 165

Swept volumecu.in 928 824l 15.2 13.5

Output per SAE J1995hp 540 525kW 403 392

Typical Engine Load % 85% 90%Duty Cycle (time at full load) % 50%(1) 100%(2)

Designation XAS 1800 CD7

XAS 1800 JD7

Capacity of oil sump:

- Refill (max.)US gal 19 15.8l 72 60

Capacity of cooling systemUS gal 23 23l 87 87

Capacity of compressor oil system

Capacity of fuel tanks (tandem)

Capacity of fuel tanks (wagon)

Capacity of fuel tanks (skid)

Designation

Length

Width

Height

Designation

effects that the products and services may have, when

rmine strict requirements.ed, as well as environmental perils and dangers to health

g works and are therefore almost infinitely recyclable.

s.cal disposal regulations. electronics, wiring, hoses, insulation and plastic parts.

accordance with applicable local disposal regulations.

sal of the product you help prevent possible negative

- 77 -

Disposal

GeneralWhen developing products and services, Atlas Copco tries to understand, address, and minimize the negative environmentalbeing manufactured, distributed, used and disposed.Recycling and disposal policy are part of the development of all Atlas Copco products. Atlas Copco company standards deteMaterial selection, substantial recyclability, disassembly possibilities and separability of materials and assemblies are considerduring the recycling and disposal of the unavoidable rates of non-recyclable materials.Your Atlas Copco compressor consists for the most part of metallic materials, that can be remelted in steelworks and smeltinThe plastic used is labelled; sorting and fractioning of the materials for recycling in the future is forseen

DISPOSAL OF MATERIALSDispose of contaminated substances and material separately, in accordance with locally applicable environmental legislationBefore dismantling a machine at the end of its operating lifetime drain and dispose of all fluids of according the applicable loRemove the batteries. Do not throw batteries into the fire (explosion risk) or residual waste. Separate the machine into metal,Dispose all components according to the applicable disposal regulations.Remove spilled fluid mechanically; pick up the rest using an absorbing agent (for example sand, sawdust) and dispose of it inDo not drain into the sewage system or surface water.

This concept can only succeed with your help. Support us by disposing professionally. By assuring correct dispoconsequences for environment and health as a result of inappropriate waste handling.Recycling and re-usage of material help preserve natural resources.

........................................................................................

Date By: initials

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Maintenance Log

Compressor ....................................................................................................................... Customer....................................

Serial number

Service hours Maintenance action

..................................................................................

te By: initials

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Maintenance Log

Compressor ....................................................................................................................... Customer..........................................

Serial number

Service hours Maintenance action Da

........................................................................................

Date By: initials

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Maintenance Log

Compressor ....................................................................................................................... Customer....................................

Serial number

Service hours Maintenance action

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