XA(S) 137 DD - XA(S) 300 DD7XA(S) 137 DDG - XA(S) 300 DD7GXAHS 107 DD - XAHS 250 DD7

Instruction Manual For Portable CompressorsEnglish

Engine Deutz BF4M2011

ATLAS COPCO - PORTABLE AIR DIVISIONwww.atlascopco.com

Printed matter N°2954 3170 00

09/2007

Instruction Manualfor Portable Compressors

XA(S) 137 DD - XA(S) 300 DD7XA(S) 137 DDG - XA(S) 300 DD7GXAHS 107 DD - XAHS 250 DD7

Warranty and Liability LimitationUse only authorized parts.Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or ProductLiability.The manufacturer does not accept any liability for any damage arising for modifications, additions orconversions made without the manufacturer's approval in writing.While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does notassume responsibility for possible errors.

Copyright 2007, Atlas Copco Airpower n.v., Antwerp, Belgium.Any unauthorized use or copying of the contents or any part thereof is prohibited.This applies in particular to trademarks, model denominations, part numbers and drawings.

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PrefacePlease read the following instructions carefullybefore starting to use your compressor.It is a solid, safe and reliable machine, builtaccording to the latest technology. Follow theinstructions in this booklet and we guarantee youyears of troublefree operation.Always keep the manual available near the machine.In all correspondence always mention thecompressor type and serial number, shown on thedata plate.The company reserves the right to make changeswithout prior notice.

Table of contents1 Safety precautions for portable

compressors with generator ...................... 71.1 Introduction .................................................. 71.2 General safety precautions ........................... 81.3 Safety during transport and installation ....... 91.4 Safety during use and operation................... 91.5 Safety during maintenance and repair........ 111.6 Tool applications safety ............................. 121.7 Specific safety precautions......................... 13

2 Leading particulars .................................. 142.1 Description of safety pictograms

used in this manual..................................... 142.2 General description .................................... 14

3 Main Parts................................................. 163.1 Compressor regulating system ................... 203.1.1 Overview (Load condition)................... 203.1.2 Air flow.................................................. 213.1.3 Oil system .............................................. 213.1.4 Continuous regulating system................ 223.2 Electrical system ........................................ 243.2.1 Description............................................. 273.3 Markings and information labels ............... 28

4 Operating instructions ............................. 294.1 Parking, towing and lifting instructions ..... 294.1.1 Parking instructions ............................... 294.1.2 Towing instructions ............................... 304.1.3 Height adjustment .................................. 314.1.4 Lifting instructions................................. 31

4.2 Starting/Stopping ....................................... 324.2.1 Before starting ....................................... 324.2.2 Control panel (with cold start; option)... 324.2.3 Control panel (without cold start).......... 344.2.4 Generator function

(XAS 137 DdG - XA(S) 300 DD7G) .... 364.2.5 During operation .................................... 374.2.6 Stopping procedure ................................ 37

5 Maintenance ............................................. 385.1 Use of service paks .................................... 385.2 Preventive maintenance schedule

for the compressor...................................... 385.3 Lubrication oils .......................................... 405.4 Oil level check ........................................... 425.4.1 Check engine oil level ........................... 425.4.2 Check compressor oil level.................... 425.5 Oil and oil filter change ............................. 435.5.1 Engine oil and oil filter change.............. 435.5.2 Compressor oil and oil filter change...... 435.6 Cleaning coolers......................................... 445.7 Battery care ................................................ 445.7.1 Electrolyte.............................................. 445.7.2 Activating a dry-charged battery ........... 455.7.3 Recharging a battery .............................. 455.7.4 Battery maintenance .............................. 455.8 Storage ....................................................... 455.9 Service paks ............................................... 455.10 Service kits................................................. 455.11 Compressor element overhaul.................... 455.12 Liability...................................................... 45

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6 Adjustments and servicing procedures .. 466.1 Adjustment of the

continuous regulating system ..................... 466.2 Air filter engine/compressor....................... 486.2.1 Servicing ................................................ 486.2.2 Main parts .............................................. 486.2.3 Cleaning the dust trap ............................ 486.2.4 Cleaning instructions filter element ....... 486.2.5 Replacing the air filter element .............. 496.3 Air receiver................................................. 506.4 Safety valve ................................................ 506.5 Fuel system................................................. 506.6 Brake (= option) adjustment....................... 516.7 Brake shoe adjustment................................ 516.7.1 Test procedure of

brake cable adjustment........................... 526.7.2 Brake cable adjustment .......................... 53

7 Problem solving ........................................ 54

8 Available options ...................................... 57

9 Technical specifications ........................... 589.1 Torque values ............................................. 589.1.1 For general applications ......................... 589.1.2 For important assemblies ....................... 589.2 Settings of shutdown switches

and safety valves ........................................ 599.3 Compressor/Engine/

Generator specifications ............................. 609.3.1 Reference conditions.............................. 609.3.2 Limitations ............................................. 619.3.3 Performance data.................................... 639.3.4 Design data............................................. 66

9.3.5 Design data for generator....................... 68

10 Data plate .................................................. 69

11 Disposal ..................................................... 7011.1 General ....................................................... 7011.2 Disposal of materials.................................. 70

12 Maintenance Log ...................................... 71

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Safety precautions for portable compressors with generator

INTRODUCTION

The policy of Atlas Copco is to provide the users oftheir equipment with safe, reliable and efficientproducts. Factors taken into account are amongothers:- the intended and predictable future use of the

products, and the environments in which they areexpected to operate,

- applicable rules, codes and regulations,- the expected useful product life, assuming proper

service and maintenance,- providing the manual with up-to-date

information.Before handling any product, take time to read therelevant instruction manual. Besides giving detailedoperating instructions, it also gives specificinformation about safety, preventive maintenance,etc.Keep the manual always at the unit location, easyaccessible to the operating personnel.See also the safety precautions of the engine andpossible other equipment, which are separately sentalong or are mentioned on the equipment or parts ofthe unit.These safety precautions are general and somestatements will therefore not always apply to aparticular unit.Only people that have the right skills should beallowed to operate, adjust, perform maintenance orrepair on Atlas Copco equipment.

It is the responsibility of management to appointoperators with the appropriate training and skill foreach category of job.Skill level 1: OperatorAn operator is trained in all aspects of operating theunit with the push-buttons, and is trained to know thesafety aspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unitthe same as the operator. In addition, the mechanicaltechnician is also trained to perform maintenance andrepair, as described in the instruction manual, and isallowed to change settings of the control and safetysystem. A mechanical technician does not work onlive electrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the samequalifications as both the operator and the mechanicaltechnician. In addition, the electrical technician maycarry out electrical repairs within the variousenclosures of the unit. This includes work on liveelectrical components.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer orits agent to perform complex repairs or modificationsto the equipment.In general it is recommended that not more than twopeople operate the unit, more operators could lead tounsafe operating conditions.

Take necessary steps to keep unauthorized personsaway from the unit and eliminate all possible sourcesof danger at the unit.When handling, operating, overhauling and/orperforming maintenance or repair on Atlas Copcoequipment, the mechanics are expected to use safeengineering practices and to observe all relevant localsafety requirements and ordinances. The followinglist is a reminder of special safety directives andprecautions mainly applicable to Atlas Copcoequipment.These safety precautions apply to machineryprocessing or consuming air. Processing of any othergas requires additional safety precautions typical tothe application and are not included herein.Neglecting the safety precautions may endangerpeople as well as environment and machinery:- endanger people due to electrical, mechanical or

chemical influences,- endanger the environment due to leakage of oil,

solvents or other substances,- endanger the machinery due to function failures.All responsibility for any damage or injury resultingfrom neglecting these precautions or by non-observance of ordinary caution and due care requiredin handling, operating, maintenance or repair, also ifnot expressly mentioned in this instruction manual, isdisclaimed by Atlas Copco.

To be read attentively and acted accordingly before towing, lifting, operating, performingmaintenance or repairing the unit.

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The manufacturer does not accept any liability for anydamage arising from the use of non-original parts andfor modifications, additions or conversions madewithout the manufacturer’s approval in writing.If any statement in this manual does not comply withlocal legislation, the stricter of the two shall beapplied.Statements in these safety precautions should not beinterpreted as suggestions, recommendations orinducements that it should be used in violation of anyapplicable laws or regulations.

GENERAL SAFETY PRECAUTIONS

1 The owner is responsible for maintaining the unitin a safe operating condition. Unit parts andaccessories must be replaced if missing orunsuitable for safe operation.

2 The supervisor, or the responsible person, shall atall times make sure that all instructions regardingmachinery and equipment operation andmaintenance are strictly followed and that themachines with all accessories and safety devices,as well as the consuming devices, are in goodrepair, free of abnormal wear or abuse, and arenot tampered with.

3 Whenever there is an indication or any suspicionthat an internal part of a machine is overheated,the machine shall be stopped but no inspectioncovers shall be opened before sufficient coolingtime has elapsed; this to avoid the risk ofspontaneous ignition of oil vapour when air isadmitted.

4 Normal ratings (pressures, temperatures, speeds,etc.) shall be durably marked.

5 Operate the unit only for the intended purpose andwithin its rated limits (pressure, temperature,speeds, etc.).

6 The machinery and equipment shall be kept clean,i.e. as free as possible from oil, dust or otherdeposits.

7 To prevent an increase in working temperature,inspect and clean heat transfer surfaces (coolerfins, intercoolers, water jackets, etc.) regularly.See the maintenance schedule. See thePreventive maintenance schedule for thecompressor.

8 All regulating and safety devices shall bemaintained with due care to ensure that theyfunction properly. They may not be put out ofaction.

9 Care shall be taken to avoid damage to safetyvalves and other pressure-relief devices,especially to avoid plugging by paint, oil coke ordirt accumulation, which could interfere with thefunctioning of the device.

10 Pressure and temperature gauges shall be checkedregularly with regard to their accuracy. They shallbe replaced whenever outside acceptabletolerances.

11 Safety devices shall be tested as described in themaintenance schedule of the instruction manualto determine that they are in good operatingcondition. See the Preventive maintenanceschedule for the compressor.

12 Mind the markings and information labels on theunit.

13 In the event the safety labels are damaged ordestroyed, they must be replaced to ensureoperator safety.

14 Keep the work area neet. Lack of order willincrease the risk of accidents.

15 When working on the unit, wear safety clothing.Depending on the kind of activities these are:safety glasses, ear protection, safety helmet(including visor), safety gloves, protectiveclothing, safety shoes. Do not wear the hair longand loose (protect long hair with a hairnet), orwear loose clothing or jewelry.

16 Take precautions against fire. Handle fuel, oil andanti-freeze with care because they areinflammable substances. Do not smoke orapproach with naked flame when handling suchsubstances. Keep a fire-extinguisher in thevicinity.

17 Portable compressors with generator (withearthing pin):Earth the generator as well as the load properly.

18 Portable compressors with generator IT:Note: This generator is built to supply a sheeralternating current IT network.Earth the load properly.

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SAFETY DURING TRANSPORT AND INSTALLATION

To lift a unit, all loose or pivoting parts, e.g. doors andtowbar, shall first be securely fastened.Do not attach cables, chains or ropes directly to thelifting eye; apply a crane hook or lifting shacklemeeting local safety regulations. Never allow sharpbends in lifting cables, chains or ropes.Helicopter lifting is not allowed. It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas. Lifting acceleration and retardationshall be kept within safe limits.1 Before towing the unit:

- ascertain that the pressure vessel(s) is (are)depressurized,

- check the towbar, the brake system and thetowing eye. Also check the coupling of thetowing vehicle,

- check the towing and brake capability of thetowing vehicle,

- check that the towbar, jockey wheel or standleg is safely locked in the raised position,

- ascertain that the towing eye can swivel freelyon the hook,

- check that the wheels are secure and that thetyres are in good condition and inflatedcorrectly,

- connect the signalisation cable, check all lightsand connect the pneumatic brake couplers,

- attach the safety break-away cable or safetychain to the towing vehicle,

- remove wheel chocks, if applied, anddisengage the parking brake.

2 To tow a unit use a towing vehicle of amplecapacity. Refer to the documentation of thetowing vehicle.

3 If the unit is to be backed up by the towingvehicle, disengage the overrun brake mechanism(if it is not an automatic mechanism).

4 Never exceed the maximum towing speed of theunit (mind the local regulations).

5 Place the unit on level ground and apply theparking brake before disconnecting the unit fromthe towing vehicle. Unclip the safety break-awaycable or safety chain. If the unit has no parkingbrake or jockey wheel, immobilize the unit byplacing chocks in front of and/or behind thewheels. When the towbar can be positionedvertically, the locking device must be applied andkept in good order.

6 To lift heavy parts, a hoist of ample capacity,tested and approved according to local safetyregulations, shall be used.

7 Lifting hooks, eyes, shackles, etc., shall never bebent and shall only have stress in line with theirdesign load axis. The capacity of a lifting devicediminishes when the lifting force is applied at anangle to its load axis.

8 For maximum safety and efficiency of the liftingapparatus all lifting members shall be applied asnear to perpendicular as possible. If required, alifting beam shall be applied between hoist andload.

9 Never leave a load hanging on a hoist.10 A hoist has to be installed in such a way that the

object will be lifted perpendicular. If that is notpossible, the necessary precautions must be takento prevent load-swinging, e.g. by using twohoists, each at approximately the same angle notexceeding 30° from the vertical.

11 Locate the unit away from walls. Take allprecautions to ensure that hot air exhausted fromthe engine and driven machine cooling systemscannot be recirculated. If such hot air is taken inby the engine or driven machine cooling fan, thismay cause overheating of the unit; if taken in forcombustion, the engine power will be reduced.

12 The electrical connections shall correspond tolocal codes. The machines shall be earthed andprotected against short circuits by fuses or circuitbreakers.

13 Never connect the generator outlets to aninstallation which is also connected to a publicmains.

14 Before connecting a load, switch off thecorresponding circuit breaker, and check whetherfrequency, voltage, current and power factorcomply with the ratings of the generator.

SAFETY DURING USE AND OPERATION

1 When the unit has to operate in a fire-hazardousenvironment, each engine exhaust has to beprovided with a spark arrestor to trap incendiarysparks.

2 The exhaust contains carbon monoxide which is alethal gas. When the unit is used in a confinedspace, conduct the engine exhaust to the outsideatmosphere by a pipe of sufficient diameter; dothis in such a way that no extra back pressure iscreated for the engine. If necessary, install anextractor. Observe any existing local regulations.Make sure that the unit has sufficient air intakefor operation. If necessary, install extra air intakeducts.

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3 When operating in a dust-laden atmosphere, placethe unit so that dust is not carried towards it by thewind. Operation in clean surroundingsconsiderably extends the intervals for cleaningthe air intake filters and the cores of the coolers.

4 Close the compressor air outlet valve beforeconnecting or disconnecting a hose. Ascertainthat a hose is fully depressurized beforedisconnecting it. Before blowing compressed airthrough a hose or air line, ensure that the open endis held securely, so that it cannot whip and causeinjury.

5 The air line end connected to the outlet valvemust be safeguarded with a safety cable, attachednext to the valve.

6 No external force may be exerted on the air outletvalves, e.g. by pulling on hoses or by installingauxiliary equipment directly to a valve, e.g. awater separator, a lubricator, etc. Do not step onthe air outlet valves.

7 Never move a unit when external lines or hosesare connected to the outlet valves, to avoiddamage to valves, manifold and hoses.

8 Do not use compressed air from any type ofcompressor, without taking extra measures, forbreathing purposes as this may result in injury ordeath. For breathing air quality, the compressedair must be adequately purified according to locallegislation and standards. Breathing air mustalways be supplied at stable, suitable pressure.

9 Distribution pipework and air hoses must be ofcorrect diameter and suitable for the workingpressure. Never use frayed, damaged ordeteriorated hoses. Replace hoses and flexiblesbefore the lifetime expires. Use only the correcttype and size of hose end fittings and connections.

10 If the compressor is to be used for sand-blastingor will be connected to a common compressed-air

system, fit an appropriate non-return valve (checkvalve) between compressor outlet and theconnected sand-blasting or compressed-airsystem. Observe the right mounting position/direction.

11 Before removing the oil filler plug, ensure that thepressure is released by opening an air outletvalve.

12 Never remove a filler cap of the cooling watersystem of a hot engine. Wait until the engine hassufficiently cooled down.

13 Never refill fuel while the unit is running, unlessotherwise stated in the Atlas Copco InstructionBook. Keep fuel away from hot parts such as airoutlet pipes or the engine exhaust. Do not smokewhen fuelling. When fuelling from an automaticpump, an earthing cable should be connected tothe unit to discharge static electricity. Never spillnor leave oil, fuel, coolant or cleansing agent in oraround the unit.

14 All doors shall be shut during operation so as notto disturb the cooling air flow inside thebodywork and/or render the silencing lesseffective. A door should be kept open for a shortperiod only e.g. for inspection or adjustment.

15 Periodically carry out maintenance worksaccording to the maintenance schedule.

16 Stationary housing guards are provided on allrotating or reciprocating parts not otherwiseprotected and which may be hazardous topersonnel. Machinery shall never be put intooperation, when such guards have been removed,before the guards are securely reinstalled.

17 Noise, even at reasonable levels, can causeirritation and disturbance which, over a longperiod of time, may cause severe injuries to thenervous system of human beings.

When the sound pressure level, at any point wherepersonnel 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 continuouslybeing present in the room,

- below 85 dB(A): no action needs to be takenfor occasional visitors staying a limited timeonly,

- above 85 dB(A): room to be classified as anoise-hazardous area and an obvious warningshall be placed permanently at each entranceto alert people entering the room, for evenrelatively short times, about the need to wearear protectors,

- above 95 dB(A): the warning(s) at theentrance(s) shall be completed with therecommendation that also occasional visitorsshall wear ear protectors,

- above 105 dB(A): special ear protectors thatare adequate for this noise level and thespectral composition of the noise shall beprovided and a special warning to that effectshall be placed at each entrance.

18 Insulation or safety guards of parts thetemperature of which can be in excess of 80 °C(175 °F) and which may be accidentally touchedby personnel shall not be removed before theparts have cooled to room temperature.

19 Never operate the unit in surroundings wherethere is a possibility of taking in flammable ortoxic fumes.

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

21 When using compressed air or inert gas to cleandown equipment, do so with caution and use the

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appropriate protection, at least safety glasses, forthe operator as well as for any bystander. Do notapply compressed air or inert gas to your skin ordirect an air or gas stream at people. Never use itto clean dirt from your clothes.

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

23 Safety shoes should be compulsory in anyworkshop and if there is a risk, however small, offalling objects, wearing of a safety helmet shouldbe included.

24 If there is a risk of inhaling hazardous gases,fumes or dust, the respiratory organs must beprotected and depending on the nature of thehazard, so must the eyes and skin.

25 Remember that where there is visible dust, thefiner, invisible particles will almost certainly bepresent too; but the fact that no dust can be seenis not a reliable indication that dangerous,invisible dust is not present in the air.

26 Never operate the unit at pressures or speedsbelow or in excess of its limits as indicated in thetechnical specifications.

27 Never operate the generator in excess of its limitsas indicated in the technical specifications andavoid long no-load sequences.

28 Never operate the generator in a humidatmosphere. Excessive moisture causesworsening of the generator insulation.

29 Do not open electrical cabinets, cubicles or otherequipment while voltage is supplied. If suchcannot be avoided, e.g. for measurements, tests oradjustments, have the action carried out by aqualified electrician only, with appropriate tools,and ascertain that the required bodily protectionagainst electrical hazards is applied.

30 Never touch the power terminals during operationof the machine.

31 Whenever an abnormal condition arises, e.g.excessive vibration, noise, odour, etc., switch thecircuit breakers to OFF and stop the engine.Correct the faulty condition before restarting.

32 Check the electric cables regularly. Damagedcables and insufficient lightening of connectionsmay cause electric shocks. Whenever damagedwires or dangerous conditions are observed,switch the circuit breakers to OFF and stop theengine. Replace the damaged wires or correct thedangerous condition before restarting. Make surethat all electric connections are securelytightened.

33 Avoid overloading the generator. The generator isprovided with circuit breakers for overloadprotection. When a breaker has tripped, reducethe concerned load before restarting.

34 If the generator is used as stand-by for the mainssupply, it must not be operated without controlsystem which automatically disconnects thegenerator from the mains when the mains supplyis restored.

35 Never remove the cover of the output terminalsduring operation. Before connecting ordisconnecting wires, switch off the load and thecircuit breakers, stop the machine and make surethat the machine cannot be started inadvertentlyor there is any residual voltage on the powercircuit.

36 Running the generator at low load for longperiods will reduce the lifetime of the engine.

SAFETY DURING MAINTENANCE AND REPAIR

Maintenance, overhaul and repair work shall only becarried out by adequately trained personnel; ifrequired, under supervision of someone qualified forthe job.1 Use only the correct tools for maintenance and

repair work, and only tools which are in goodcondition.

2 Parts shall only be replaced by genuine AtlasCopco replacement parts.

3 All maintenance work, other than routineattention, shall only be undertaken when the unitis stopped. Steps shall be taken to preventinadvertent starting. In addition, a warning signbearing a legend such as ”work in progress; donot start” shall be attached to the startingequipment. On engine-driven units the battery shall bedisconnected and removed or the terminalscovered by insulating caps. On electrically driven units the main switch shallbe locked in open position and the fuses shall betaken out. A warning sign bearing a legend suchas ”work in progress; do not supply voltage” shallbe attached to the fuse box or main switch.

4 Before dismantling any pressurized component,the compressor or equipment shall be effectivelyisolated from all sources of pressure and the entiresystem shall be relieved of pressure. Do not relyon non-return valves (check valves) to isolatepressure systems. In addition, a warning signbearing a legend such as ”work in progress; donot open” shall be attached to each of the outletvalves.

5 Prior to stripping an engine or other machine orundertaking major overhaul on it, prevent allmovable parts from rolling over or moving.

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6 Make sure that no tools, loose parts or rags are leftin or on the machine. Never leave rags or looseclothing near the engine air intake.

7 Never use flammable solvents for cleaning (fire-risk).

8 Take safety precautions against toxic vapours ofcleaning liquids.

9 Never use machine parts as a climbing aid.10 Observe scrupulous cleanliness during

maintenance and repair. Keep away dirt, coverthe parts and exposed openings with a clean cloth,paper or tape.

11 Never weld on or perform any operationinvolving heat near the fuel or oil systems. Fueland oil tanks must be completely purged, e.g. bysteam-cleaning, before carrying out suchoperations. Never weld on, or in any way modify,pressure vessels. Disconnect the alternator cablesduring arc welding on the unit.

12 Support the towbar and the axle(s) securely ifworking underneath the unit or when removing awheel. Do not rely on jacks.

13 Do not remove any of, or tamper with, the sound-damping material. Keep the material free of dirtand liquids such as fuel, oil and cleansing agents.If any sound-damping material is damaged,replace it to prevent the sound pressure level fromincreasing.

14 Use only lubricating oils and greasesrecommended or approved by Atlas Copco or themachine manufacturer. Ascertain that theselected lubricants comply with all applicablesafety regulations, especially with regard toexplosion or fire-risk and the possibility ofdecomposition or generation of hazardous gases.Never mix synthetic with mineral oil.

15 Protect the engine, alternator, air intake filter,electrical and regulating components, etc., toprevent moisture ingress, e.g. when steam-cleaning.

16 When performing any operation involving heat,flames or sparks on a machine, the surroundingcomponents shall first be screened with non-flammable material.

17 Never use a light source with open flame forinspecting the interior of a machine.

18 When repair has been completed, the machineshall be barred over at least one revolution forreciprocating machines, several revolutions forrotary ones to ensure that there is no mechanicalinterference within the machine or driver. Checkthe direction of rotation of electric motors whenstarting up the machine initially and after anyalteration to the electrical connection(s) or switchgear, to check that the oil pump and the fanfunction properly.

19 Maintenance and repair work should be recordedin an operator’s logbook for all machinery.Frequency and nature of repairs can reveal unsafeconditions.

20 When hot parts have to be handled, e.g. shrinkfitting, special heat-resistant gloves shall be usedand, if required, other body protection shall beapplied.

21 When using cartridge type breathing filterequipment, ascertain that the correct type ofcartridge is used and that its useful service life isnot surpassed.

22 Make sure that oil, solvents and other substanceslikely to pollute the environment are properlydisposed of.

23 Before clearing the unit for use after maintenanceor overhaul, check that operating pressures,temperatures and speeds are correct and that thecontrol and shutdown devices function correctly.

TOOL APPLICATIONS SAFETY

Apply the proper tool for each job. With theknowledge of correct tool use and knowing thelimitations of tools, along with some common sense,many accidents can be prevented.Special service tools are available for specific jobsand should be used when recommended. The use ofthese tools will save time and prevent damage toparts.

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SPECIFIC SAFETY PRECAUTIONS

BatteriesWhen servicing batteries, always wear protectingclothing and glasses.1 The electrolyte in batteries is a sulphuric acid

solution which is fatal if it hits your eyes, andwhich can cause burns if it contacts your skin.Therefore, be careful when handling batteries,e.g. when checking the charge condition.

2 Install a sign prohibiting fire, open flame andsmoking at the post where batteries are beingcharged.

3 When batteries are being charged, an explosivegas mixture forms in the cells and might escapethrough the vent holes in the plugs. Thus anexplosive atmosphere may form around thebattery if ventilation is poor, and can remain inand around the battery for several hours after ithas been charged. Therefore:- never smoke near batteries being, or having

recently been, charged,- never break live circuits at battery terminals,

because a spark usually occurs.4 When connecting an auxiliary battery (AB) in

parallel to the unit battery (CB) with boostercables: connect the + pole of AB to the + pole ofCB, then connect the - pole of CB to the mass ofthe unit. Disconnect in the reverse order.

Pressure vessels(according to directive 87/404/EEC annex II § 2)Maintenance/installation requirements:1 The vessel can be used as pressure vessel or as

separator and is designed to hold compressed airfor the following application:- pressure vessel for compressor,- medium AIR/OIL,and operates as detailed on the data plate of thevessel:- the maximum working pressure ps in bar (psi),- the maximum working temperature Tmax in

°C (°F),- the minimum working temperature Tmin in °C

(°F),- the capacity of the vessel V in l (US gal, Imp

gal, cu.ft).2 The pressure vessel is only to be used for the

applications as specified above and in accordancewith the technical specifications. Safety reasonsprohibit any other applications.

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

4 No welding or heat treatment of any kind ispermitted to those vessel walls which are exposedto pressure.

5 The vessel is provided and may only be used withthe required safety equipment such asmanometer, overpressure control devices, safetyvalve, etc.

6 Draining of condensate shall be performedregularly when vessel is in use.

7 Installation, design and connections should not bechanged.

8 Bolts of cover and flanges may not be used forextra fixation.

Safety valvesAll adjustments or repairs are to be done by anauthorized representative of the valve supplier (seealso Preventive maintenance schedule for thecompressor).

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Leading particularsDESCRIPTION OF SAFETY PICTOGRAMS USED IN THIS MANUAL

GENERAL DESCRIPTION

The compressors type XA(S) 137 DD - XA(S) 300DD7, XA(S) 137 DDG - XA(S) 300 DD7G andXAHS 107 DD - XAHS 250 DD7 are silenced,single-stage, oil-injected screw compressors, built fora nominal effective working pressure, ranging from7 bar (101.5 psi) up to 12 bar (174 psi) (see chapterTechnical specifications).

EngineThe compressors are driven by an oil-cooled dieselengine.The engine’s power is transmitted to the compressorthrough 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. Theelement delivers pulsation-free air.Injected oil is used for sealing, cooling andlubricating purposes.

Compressor oil systemThe oil is boosted by air pressure. The system has nooil pump.The oil is removed from the air, in the air/oil vessel atfirst by centrifugal force, secondly by the oil separatorelement.The vessel is provided with an oil level indicator.

RegulationThe compressor is provided with a continuousregulating system and a blow-down valve which isintegrated in the unloader assembly. The valve isclosed during operation by air receiver pressure andopens by air receiver pressure via the compressorelement when the compressor is stopped.When the air consumption increases, the air receiverpressure will decrease and vice versa.This receiver pressure variation is sensed by theregulating valve which, by means of control air to theunloader and engine speed regulator, matches the airoutput to the air consumption. The air receiverpressure is maintained between the pre-selectedworking pressure and the corresponding unloadingpressure.

This symbol draws your attention todangerous situations. The operationconcerned may endanger persons andcause injuries.

This symbol is followed bysupplementary information.

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Cooling systemThe engine is equipped with an oil cooler. Allcompressors are equipped with an oil cooler. The cooling air is generated by a fan, driven by theengine.

Safety devicesA thermal shut-down switch protects the compressoragainst overheating. The air receiver is provided witha safety valve.The engine is equipped with low oil pressure and highoil temperature shut-down switches.

Frame and axleThe compressor/engine unit is supported by rubberbuffers in the frame.The standard unit has a non-adjustable towbar with atowing eye.As an option the unit can be equipped with anadjustable towbar, an overrun and parking brake andtowing eyes type DIN, ball, ITA, GB, NATO, AC(France), (see chapter Available options).The braking system consists of an integrated parkingbrake and overrunbrake. When driving backwards theoverrunbrake is not engaged automatically.

BodyworkThe bodywork has openings at the shaped front andrear end for the intake and outlet of cooling air andhinged door for maintenance and service operations.The bodywork is internally lined with sound-absorbing material.

Lifting eyeA lifting eye is accessible when the small door at thetop of the unit is unlocked.

Control panelThe control panel grouping the air pressure gauge,control switch etc., is placed in the center at the rearend.

Data plateThe compressor is furnished with a data plateshowing the product code, the unit number and theworking pressure (see chapter Data plate).

Serial numberThe serial number is located on the right-hand sidetowards the front on the upper edge of the frame andalso on the data plate.

Generator - XA(S) 137 DDG - XA(S) 300 DD7GThe built-in generator is driven by a multi V-beltdrive. The generated current can be drawn via3 sockets (3 x 16 A, 2 x 3 phases, 1 x 1 phase).The compressor and the generator of the XA(S) 137DDG - XA(S) 300 DD7G may be usedsimultaneously.

- 15 -

Main Parts

(E)

(EP)

(AOV)

(VI)(SV)

(OLG)(FPco)

(RV)(AR)

(CP)

(OFce)

(CE)(FT)

(AF)

(FCft)

(A)(FF)

(DSe)(FCeo)

(OCce/OCe)

(BH)

(TB)

(F)

(D)

(FCft)

(VV)

XA(S) 137 DD - XA(S) 300 DD7 and XAHS 107 DD - XAHS 250 DD7 with some options

- 16 -

Reference NameA AlternatorAF Air FilterAOV Air Outlet ValvesAR Air ReceiverBH Brake HandleCE Compressor ElementCP Control PanelD Data plateDSe Engine Oil Level DipstickE EngineEP Exhaust PipeF FanFCeo Filler Cap (engine oil)FCft Filler Cap (fuel tank)FF Fuel FilterFPco Filler Plug (oil compressor element)FT Fuel Tank

Reference NameOCce Oil Cooler (compressor element)OCe Oil Cooler (engine)OFce Oil Filter (compressor element)OLG Oil Level Gauge (compressor

element)RV Regulating ValveSV Safety ValveTB TowbarVI Vacuum IndicatorVV Vacuator Valve

- 17 -

(E)

(EP)

(AOV)

(VI)(SV)

(OLG)(FPco)

(RV)(AR)

(G)

(CPg)

(CP)

(OFce)

(CE)(FT)

(AF)

(FCft)

(A)(FF)

(DSe)(FCeo)

(OCce/OCe)

(BH)

(TB)

(F)

(D)

(FCft)

(VV)

XA(S) 137 DDG - XA(S) 300 DD7G with some options

- 18 -

Reference NameA AlternatorAF Air FilterAOV Air Outlet ValvesAR Air ReceiverBH Brake HandleCE Compressor ElementCP Control PanelCPg Control Panel GeneratorD Data plateDPoc Drain Plug Oil CoolerDSe Engine Oil Level DipstickE EngineEP Exhaust PipeF FanFCeo Filler Cap (engine oil)FCft Filler Cap (fuel tank)FF Fuel FilterFPco Filler Plug (oil compressor element)FT Fuel TankG Generator

Reference NameOCce Oil Cooler (compressor element)OCe Oil Cooler (engine)OFce Oil Filter (compressor element)OFe Oil Filter (engine)OLG Oil Level Gauge (compressor

element)RV Regulating ValveSL Support LegSV Safety ValveTB TowbarVI Vacuum IndicatorVV Vacuator Valve

- 19 -

COMPRESSOR REGULATING SYSTEM

OVERVIEW (LOAD CONDITION)

(BOV)

(AF)

(DP)(NRV) (FN)

(UV)(UA)(VH)(BDV)(CV)

(CH)

(AOV)

(RV)

(VV)

(VI)

(SV)

(FR)

(PG)

(AR)

(DP)

(OLG)(SL)

(FP)

(SL)(OF)

(CE)

(DP)

(TS)(F)

(OCce)(E)

(SC)

(OS)

(SVa)

(SR)

Reference NameAF Air FilterAOV Air Outlet ValvesAR Air ReceiverBDV Blow Down ValveBOV Blow Off ValveCE Compressor ElementCH Coupling HousingCV Check ValveDP Drain PlugE EngineF FanFN Flow NozzleFP Filler PlugFR Flow RestrictorNRV Non Return ValveOCce Oil Cooler (compressor element)OF Oil FilterOLG Oil Level GaugeOS Oil SeparatorPS Pressure SensorRV Regulating Valve

- 20 -

AIR FLOW

The system comprises:AF Air filterAR/OS Air receiver/oil separatorCE Compressor elementUA/UV Unloader assembly with unloader valveBDV Blow-down valve

Air drawn through the airfilter (AF) into thecompressor element (CE) is compressed. At theelement outlet, compressed air and oil pass into the airreceiver/oil separator (AR/OS).The check valve (CV) prevents blow-back ofcompressed air when the compressor is stopped. Inthe air receiver/oil separator (AR/OS), most of the oilis removed from the air/oil mixture; the remaining oilis removed by the separator element.The oil collects in the receiver and on the bottom ofthe separator element.The air leaves the receiver via a restriction (FN)which prevents the receiver pressure from droppingbelow the minimum working pressure (specified insection Limitations), even when the air outlet valvesare open. This ensures adequate oil injection andprevents oil consumption.A temperature switch (TS) and a working pressuregauge (PG) are comprised in the system.A blow-down valve (BDV) is fitted in the unloaderassembly to automatically depressurise the airreceiver (AR) when the compressor is stopped.

OIL SYSTEM

The system comprises:AR/OS Air receiver/oil separatorOCce Oil coolerOF Oil filter

The lower part of the air receiver (AR) serves as oiltank.Air pressure forces the oil from the air receiver/oilseparator (AR/OS) through the oil cooler (OCce) andoil filter (OF) to the compressor element (CE).The compressor element has an oil gallery in thebottom of its casing. The oil for rotor lubrication,cooling and sealing is injected through holes in thegallery.Lubrication of the bearings is ensured by oil injectedinto the bearing housings.The injected oil, mixed with the compressed air,leaves the compressor element and re-enters the airreceiver, where it is separated from the air asdescribed in section Air flow. The oil that collects inthe bottom of the oil separator element is returned tothe system through scavenging line (SL), which isprovided with a flow restrictor (FR).The oil filter by-pass valve opens when the pressuredrop over the filter is above normal because of aclogged filter. The oil then by-passes the filterwithout being filtered. For this reason, the oil filtermust be replaced at regular intervals (see sectionPreventive maintenance schedule for thecompressor).

Reference NameSL Scavenge LineSR Speed RegulatorSV Safety ValveSVa Solenoid Valve Generator Action

(only for XA(S) 137 DDG - XA(S) 300 DD7G)

TS Temperature SwitchUA Unloader AssemblyUV Unloader ValveVH Vent HoleVI Vacuum Indicator

- 21 -

CONTINUOUS REGULATING SYSTEM

(BOV)

(UV)(UA)(VH)

(RV)

(AR)

(CE)

(SVa)

(SR)

- 22 -

The system comprises:RV Regulating valveUA Unloader assemblySR Speed regulator

The compressor is provided with a continuousregulating system. This system is provided with ablow-down valve which is integrated in the unloaderassembly (UA). The valve is closed during operationby air receiver pressure and opens by air receiverpressure via the compressor element when thecompressor is stopped.When the air consumption increases, the air receiverpressure will decrease and vice versa. This receiverpressure variation is sensed by the regulating valvewhich, by means of control air to the unloader,matches the air output to the air consumption. The airreceiver pressure is maintained between the pre-selected working pressure and the correspondingunloading pressure.When starting the compressor, the unloader valve(UV) is kept open by spring force, the engine runs atmaximum speed. The compressor element (CE) takesin air and pressure builds up in the receiver (AR).The air output is controlled 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.3. Blow off valve (BOV).

If the air consumption is equal to or exceeds themaximum air output, the engine speed is held atmaximum load speed and the unloading valve is fullyopen.If the air consumption is less than the maximum airoutput, the regulating valve supplies control air tounloader valve (UV) to reduce the air output andholds air receiver pressure between the normalworking pressure and the corresponding unloadingpressure of approx. 1.5 bar (22 psi) above the normalworking pressure.When the air consumption is resumed, the blow offvalve (BOV) closes and the unloader valve (UV)gradually opens the air intake and the speed regulator(SR) increases the engine speed.The construction of the regulating valve (RV) is suchthat any increase (decrease) of the air receiverpressure above the pre-set valve opening pressureresults in a proportional increase (decrease) of thecontrol pressure to the unloading valve and the speedregulator.Part of the control air is vented to atmosphere, andany condensate discharged, through the vent holes(VH).

XA(S) 137 DDG - XA(S) 300 DD7G:When the generator is switched on, the solenoid valve(SVa) via the speed regulator (SR) controls the motorand allows it to reach maximum speed (the normalcontrol system is switched off).

- 23 -

ELECTRICAL SYSTEM

All compressors are equipped with a negative earthed system.

h

22111

d10

d6d6a8a8b3

d10

d7b3 c1

1212

1817

111616

P3

K6

P2

S6

K5K5 K6

11999

1015

14

13

5

6

7

4

3

2

1

33338

121212121212121212

+G2

-

K0

K1H2

K3

S5

H1K2

K1

K3

Auxiliary

V2K0

33

S1 01

32

30

32

31

P1M1

M

S4K2

PS3

S2

Y1

K4

F1

D-

B+D+

G1 V1

K4

(9822 0841 15)

Cold Start Option.

- 24 -

Reference NameF1 Circuit breakerG1 AlternatorG2 BatteryH1 Lamp temperature alarmH2 Lamp general alarmK0 Starter solenoid (part of M1)K1 RelayK2 RelayK3 RelayK4 RelayK5-K6 Relay heater plugM1 Starter motorP1 HourmeterP2-P3 Heater plugS1 Contactswitch (Off-On-Override-

Start)S2 Temperature switch engineS3 Oil pressure switchS4 Temperature Lamptest switchS5 Temperature switch compressorS6 Coldstart switchV1 DiodeV2 DiodeY1 Fuel solenoid valve

- 25 -

b3

12

b6

13

b3b3b3

12

b6 12

34

9822 0797 01To Circuit diagram

b3

b612

b6b6

13

3

12

1313

Y2R

B

P

S75152

35K5

A2

A1

uS6

H3

W1

b6

16b0

b0

W1

16b6

N

b016

b54b54

b0

b54

W1b0

b0

N

16A16A16A

Q1

16A

NNW

1

U1 V1

WVU

8

7

6

5

4

3

2

1

K5

MX

c0

c0

c0

c0

c0

c0

c6

c6

c0 c0 c0 c6 c54

G3U1 V1 W1 N

G

16AL1L2

L3 N

NL3L2L1

X1.1

c0 c6 c54

16A

L3 N

NL2

X1.3

c0 c0 c0 c6 c54

16AL1L2

L3 N

NL3L2L1

X1.2

PE

D1K6R<

111214

R T PE

A1

A2L

XA(S) 137 DDG - XA(S) 300 DD7GThis generator is built to supply a sheeralternating current IT network.

- 26 -

DESCRIPTION

Generator function:Turn switch S6 to position 1. The solenoid valve Y2G via the speed regulator SR controls the motor and allows it to reach maximum speed (the normal control system is switched off). Lamp H1 is activated (sockets X1.1, X1.2, X1.3 are under tension).The generator can be switched off by turning switch S6 to position 0.

In the case of an insulation fault, lamp H2 of thesystem is activated. When the red lamp H2 is active,a reset can only be made by stopping and restartingthe unit.

Reference NameD1 DiodeG3 GeneratorH3 Lamp (Power control)K5 Contactor 4-poleK6 Insulation Monitoring RelayQ1 Main circuit breaker 4-poleS6 Thermal contact (N/O)S7 Switch (Generator-compressor)X1.1 Socket outletX1.2 Socket outletX1.3 Socket outletY2 Solenoid valve (Generator

operation)

- 27 -

MARKINGS AND INFORMATION LABELS

Compressor outlet temperature too high.

Compressor outlet temperature.

Compressor outlet pressure.

Dangerous outlet gases.

Danger, heat flat.

Electrocution hazard.

Atlas Copco mineral compressor oil.

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.

Hours, time.

Prohibition to open air valves without connected hoses.

Compressor loaded.

Runlamp.

Airfilter.

Compressor temperature too high.

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.

4.75 bar(69 psi) Tyre pressure.

Sound power level in accordance with Directive 2000/14/EC (expressed in dB (A)).

Sound power level in accordance with Directive 2000/14/EC (expressed in dB (A)).

Sound power level in accordance with Directive 2000/14/EC (expressed in dB (A)).

Horizontal towbar position required in case of coupling.

- 28 -

Operating instructionsPARKING, TOWING AND LIFTING INSTRUCTIONS

Safety precautions

Attention:

PARKING INSTRUCTIONS

Non-adjustable towbar with standard support leg withoutbrakes

Adjustable towbar with jockey wheel and brakes

Parking position of jockey wheel

When parking a compressor, secure support leg (1) orjockey wheel (2) to support the compressor in a levelposition. Be sure that the jockey wheel (2) is blockedby the blocking pin (4).Apply parking brake by pulling parking brake handle(3) upwards. Place the compressor as level aspossible; however, it can be operated temporarily inan out-of-level position not exceeding 15°. If thecompressor is parked on sloping ground, immobilizethe compressor by placing wheel chocks (available asoption) in front of or behind the wheels.

The operator is expected to apply allrelevant safety precautions, includingthose mentioned on the pages 7 - 13 ofthis book.

Before putting the compressor in to use,check the brake system as described insection Brake (= option) adjustment.After the first 100 km travel:Check and retighten the wheel nuts andtowbar bolts to the specified torque. Seesection Height adjustment and sectionTorque values.Check the brake adjustment. See sectionBrake (= option) adjustment.

(1)

(3)

(2)

(4)

(2)

(4) (4)

(2)

- 29 -

Locate the rear-end of the compressor upwind, awayfrom contaminated wind-streams and walls. Avoidrecirculation of exhaust air from the engine. Thiscauses overheating and engine power decrease.

TOWING INSTRUCTIONS

Label on towbar

For both non-adjustable - and adjustable towbar, thetowbar should be as level as possible and thecompressor and towing eye end in a level position.Push the hand brake lever (1) completely downwardsand connect breakaway cable (2) to the vehicle.Secure jockey wheel (3) or support leg in the highestpossible position (see figure). The jockey wheel isprevented from turning.

Before towing the compressor, ensurethat the towing equipment of the vehiclematches the towing eye or ball connectorand ensure that the service doors areclosed and locked properly.

(1)

(2)(3)

- 30 -

HEIGHT ADJUSTMENT(with adjustable towbar)

• Remove spring pin (1).• Release locking nut (2) with support tools

(Extension tube 3).• Adjust required height of the towbar.• Tighten locking nut (2) by hand first.• Secondly tighten locking nut (2) with a tightening

torque corresponding to table. With an extension tube (3) (”A” corresponding to table 1) and handforce (”B” corresponding to table 1) easy tightening is possible.

• Fix locking nut (2) with spring pin (1).

• Height adjustment should be undertaken on levelled ground and in coupled condition.

• When readjusting, make sure that the front point of the towbar is horizontal to the coupling point.

• Before starting a trip, ensure that the adjustment shaft is secure, so that the stability and safety is guaranteed while driving. If necessary tighten the locking nut (2) corresponding to table.

LIFTING INSTRUCTIONS

When lifting the compressor, the hoist has to beplaced in such a way that the compressor, which mustbe placed level, will be lifted vertically. Keep liftingacceleration and retardation within safe limits.Preferably use the lifting eye (1) herefore open thesmall door (2).

Before towing the compressor, makesure that the joints of the towbar aresecured with maximum strength withoutdamaging the towbar. Be sure that thereis no clearance between the teeth of thejoints.

(3)

(1)

(A)

(2)

(B)X

XX

For specific instruction see below!

Type M [Nm/lbf.ft.] ”A” [mm/in] ”B” [N/lbf]ZV 2000 250 - 300 / 184.5 - 221.4 600 / 23.4 420 - 500 / 94.5 - 112.5ZV 2500 350 - 400 / 258.3 - 295.2 600 / 23.4 580 - 660 / 130.5 - 148.5

Attention:

Lifting acceleration and retardationmust be kept within safe limits (max. 2g).Helicopter lifting is not allowed.Lifting is not allowed when the unit isrunning.

(1)

(2)

- 31 -

STARTING/STOPPING

BEFORE STARTING

1. Before initial start-up, prepare battery for operation if not already done. See section Battery care.

2. With the compressor standing level, check the level of the engine oil. Add oil, if necessary, to the upper mark on dipstick. Consult the Engine Operation Manual for the type and viscosity grade of the engine oil.

3. Check the level of the compressor oil. See section Compressor regulating system. The pointer of oil level gauge (OLG) should register in the green range. Add oil if necessary. See section Lubrication oils for the oil to be used.

4. Check that the fuel tank contains sufficient fuel. Top up, if necessary. Consult the Engine Operation Manual for the type of fuel.

5. Drain any water and sediment from the fuel filter until clean fuel flows from the drain cock.

6. Press vacuator valves (VV) of the air filters to remove dust.

7. Check the air filter vacuum indicators (VI). If the yellow piston reaches the red marked service range, replace the filter element. Reset the indicator by pushing the reset button.

8. Open air outlet valve to allow air flow to the atmosphere.

Before removing oil filler plug (FP),ensure that the pressure is released byopening an air outlet valve.

CONTROL PANEL (WITH COLD START; OPTION)

Reference NameP1 HourmeterPG Working pressure gaugeH1 Temperature alarm lamp (red)H2 General alarm lamp (red)S1 Start switchS4 Lamp test buttonS6 Cold start button

P1 PG H1

H2

S1

S6

S4

10 2 3

- 32 -

Before starting open the air outlet valve(s) (seesection Compressor regulating system, AOV) andpush circuit breaker button (F1) once (open hoodfirst). Circuit breaker button should now be inposition B. To preheat if necessary, first push the coldstart button S6 for a short period.

The control panel indicates receiverpressure (PG) and accumulatedoperating hours (P1).

The circuit breaker button is aprotection against unintended startingof the compressor.

A

B

(F1)

Starting procedure

1. To start, turn start switch S1 clockwise to position 1, lamp H2 (general alarm lamp) will go on.

2. Check correct operation of alarm lamps H1 and H2 by pushing lamp test button S4. Both alarm lamps (red) should go on.

3. Turn start switch S1 further clockwise into position 3.The starter motor will set the engine in motion.The maximum allowed starter time, where the starter motor is running continuously is 20 seconds.If the engine does not catch, a new attempt can be made after 30 seconds waiting.The temperature alarm lamp H1 and the general alarm lamp H2 will go out as soon as the engine has been started.

4. The start switch automatically springs back to position 1.Lamp H1 only will go on when the compressor outlet temperature is too high.

5. Close the air outlet valve(s) (AOV).

- 33 -

Before starting open the air outlet valve(s) (seesection Compressor regulating system, AOV) andpush circuit breaker button (F1) once (open hoodfirst). Circuit breaker button should now be inposition B.

CONTROL PANEL (WITHOUT COLD START)

Reference NameP1 HourmeterF1 Circuit breaker buttonPG Working pressure gaugeH1 Temperature alarm lamp (red)H2 General alarm lamp (red)S1 Start switchS4 Lamp test button

P1 PG H1

H2

S1

S410 2 3

The control panel indicates receiverpressure (PG) and accumulatedoperating hours (P1).

The circuit breaker button is aprotection against unintended startingof the compressor.

A

B

(F1)

- 34 -

Starting procedure

1. To start, turn start switch S1 clockwise to position 1, lamp H2 (general alarm lamp) will go on.

2. Check correct operation of alarm lamps H1 and H2 by pushing lamp test button S4. Both alarm lamps (red) should go on.

3. Turn start switch S1 further clockwise into position 3.The starter motor will set the engine in motion.The maximum allowed starter time, where the starter motor is running continuously is 20 seconds.If the engine does not catch, a new attempt can be made after 30 seconds waiting.The temperature alarm lamp H1 and the general alarm lamp H2 will go out as soon as the engine has been started.

4. The start switch automatically springs back to position 1.Lamp H1 only will go on when the compressor outlet temperature is too high.

5. Close the air outlet valve(s) (AOV).

- 35 -

GENERATOR FUNCTION (XAS 137 DDG - XA(S) 300 DD7G)

Control panel (generator)

Start the unit in accordance with the normalprocedure. Let the motor warm up until it reachesoperational temperature.

Generator control box

Fault situations and protective devices:• Open the left machine door and check that the

circuit breakers are up. If the circuit breakers are down, put them up (switch them on). Circuit breakers in the up position can be indicative of a serious electrical fault.

• When the red lamp H9 is activated, it means that a serious insulation fault has occurred. Reset by first switching off the motor, then restart it.

• The insulation monitoring relay K8 must be adjusted to 10 kΩ. This adjustment may not be changed.

H9 Lamp (red) X1.2 Socket 400 V/16 AX1.1 Socket 400 V/16 A X1.3 Socket 230 V/16 A

(X1.3)(H9) (X1.2) (X1.1)

Q1 Main circuit breaker 4-poleK8 Insulation monitoring relay

Before connecting an electrical device,always check the data listed on the ratingplate.

(K8)

1 2 3 4 5 6 7 8 9 10

102030

4050607080

(Q1)

- 36 -

DURING OPERATION

Regularly carry out following checks:1. That regulating valve (see section Main Parts,

RV) is correctly adjusted, i.e. starts decreasing the engine speed when reaching the preset working pressure in the receiver.

2. Check the air filter vacuum indicators (see section Main Parts, VI). If the yellow piston reaches the red marked service range, replace the filter element. Reset the indicators by pushing the reset button.

STOPPING PROCEDURE

1. Close the air outlet valves (see section Compressor regulating system, AOV).

2. Run unloaded for 3 minutes.3. Turn the start switch S1 counterclockwise (CCW)

to position 0.4. Push the circuit breaker button (F1) once (open

hood first). Circuit breaker button should now be in position A.

When the engine is running, the airoutlet valves (ball valves) must always beput in a fully opened or fully closedposition.

The doors must be closed duringoperation and may be opened for shortperiods only.

3 min

A

B

(F1)

- 37 -

MaintenanceUSE OF SERVICE PAKS

Service Paks include all genuine parts needed fornormal maintenance of both compressor and engine.Service Paks minimize downtime and keep yourmaintenance budget low.Order Service Paks at your local Atlas Copco dealer.

The schedule contains a summary of the maintenanceinstructions. Read the respective section before takingmaintenance measures.When servicing, replace all disengaged packings, e.g.gaskets, O-rings, washers.For engine maintenance refer to Engine OperationManual.

The maintenance schedule has to be seen as aguideline for units operating in a dusty environmenttypical to compressor applications. Maintenanceschedule can be adapted depending on applicationenvironment and quality of maintenance.

PREVENTIVE MAINTENANCE SCHEDULE FOR THE COMPRESSOR

Maintenance schedule Daily Initially Every 500 hours Every 1000 hoursService pakXA(H)(S) 107-137 / 250-300 DD(7)GStandard

2912 4490 05 2912 4481 06

Service pakXA(H)(S) 107-137 / 250-300 DD(7)GHeavy duty filter system (option)

2912 4492 05 2912 4491 06

Engine oil level CheckCompressor oil level CheckAir filter vacuator valves EmptyFuel filter water drain DrainAir intake vacuum indicators CheckElectrolyte level and terminals of battery Check Check CheckTyre pressure Check Check CheckLeaks in air-, oil- or fuel system Check Check CheckOil coolers Clean CleanEngine minimum and maximum speeds Check Check Check(to be continued on page 39)

- 38 -

Maintenance schedule(continuation of page 38)

Daily Initially Every 500 hours Every 1000 hours

Torque of wheel nuts Check Check CheckBrake system (if installed) Check/Adjust Check/Adjust Check/AdjustSafety valve TestDoor hinges Grease GreaseCoupling head and all its moving parts / shaft Grease GreaseJoints of height adjustment adjustable towbar Check Grease GreaseShutdown switches CheckPressure drop over separator element (2) Measure Replace (6)Fan V-belts (3) Adjust AdjustFuel tank Clean CleanCompressor oil ChangeCompressor oil filter ReplaceAir filter elements (1) ReplaceSafety cartridges (1) (option) ReplaceEngine oil (3) (4) Change ChangeEngine oil filter (3) Replace ReplaceFuel filter (3) (5) Replace ReplaceFuel prefilter (3) Replace ReplaceEngine inlet and outlet valves (3) AdjustDD/PD3 filter (option) Replace(to be continued on page 40)

- 39 -

(continuation of page 39)

Notes

1. More frequently when operating in a dusty environment.

2. Replace the element when the pressure drop exceeds 0.8 bar (11.6 psi).

3. Refer to the Deutz operation manual.4. 500 hours only valid when using

PAROIL SAE 15W40.5. In case of poor fuel quality, replace fuel

filter more frequently.6. Clean retainer when replacing element.

Keep the bolts of the housing, the liftingeye, the towbar and the axle securelytightened.Refer to section Technical specificationsand section Height adjustment for thetorque values.

LUBRICATION OILS

High-quality, mineral, hydraulic or synthesized hydrocarbon oil with rust and oxidation inhibitors and anti-foamand anti-wear properties is recommended. The viscosity grade should correspond to the ambient temperature andISO 3448, as follows:

PAROIL from Atlas Copco is the ONLY oil testedand approved for use in all engines built into AtlasCopco compressors and generators.Extensive laboratory and field endurance tests onAtlas Copco equipment have proven PAROIL tomatch all lubrication demands in varied conditions. Itmeets stringent quality control specifications toensure your equipment will run smoothly andreliably.The quality lubricant additives in PAROIL allow forextended oil change intervals without any loss inperformance or longevity.PAROIL provides wear protection under extremeconditions. Powerful oxidation resistance, highchemical stability and rust- inhibiting additives helpreduce corrosion, even within engines left idle forextended periods.PAROIL contains high quality anti-oxidants tocontrol deposits, sludge and contaminants that tend tobuild up under very high temperatures.PAROIL’s detergent additives keep sludge formingparticles in a fine suspension instead of allowing themto clog your filter and accumulate in the valve/rockercover area.

PAROIL releases excess heat efficiently, whilstmaintaining excellent bore-polish protection to limitoil consumption.PAROIL has an excellent Total Base Number (TBN)retention and more alkalinity to control acidformation.PAROIL prevents Soot build-upPAROIL is optimized for the latest low emissionEURO -3 & -2, EPA TIER II & III engines running onlow sulphur diesel for lower oil and fuel consumption.PAROIL 5W40 is a Synthetic ultra high performancediesel engine oil with a high viscosity- index. AtlasCopco PAROIL 5W40 is designed to provideexcellent lubrication from start-up in temperatures aslow as -25°C (-13°F).PAROIL 15W40 is a mineral based high performancediesel engine oil with a high viscosity- index. AtlasCopco PAROIL 15W40 is designed to provide a highlevel of performance and protection in ‘standard’ambient conditions as from -15°C (5°F).

Type of lubricant Compressor** Engine*between -25°C (-13°F) and -50°C (122°F) PAROIL S PAROIL 5W40between -10°C (14°F) and +50°C (122°F) PAROIL M PAROIL 15W40

- 40 -

*If you want to use another brand of oil,consult the Engine Operation Manual.

**It is strongly recommended to use AtlasCopco branded lubrication oils for bothcompressor and engine. If you want touse another brand of oil, consult AtlasCopco.

Never mix synthetic with mineral oil.Remark: When changing from mineral tosynthetic oil (or the other way around),you will need to do an extra rinse:After doing the complete changeprocedure to synthetic oil, run the unitfor a few minutes to allow good andcomplete circulation of the synthetic oil.Then drain the synthetic oil again andfill again with new synthetic oil. To setcorrect oil levels, proceed as in normalinstruction.

Mineral compressor oil PAROIL M

Synthetic compressor oil PAROIL S

Mineral engine oil PAROIL 15W40

Synthetic engine oil PAROIL 5W40

Liter US gal Order numbercan 5 1.3 1615 5947 00can 20 5.3 1615 5948 00barrel 210 55.2 1615 5949 00

Liter US gal Order numbercan 5 1.3 1615 5950 01can 20 5.3 1615 5951 01barrel 210 55.2 1615 5952 01container 1000 265 1604 7422 00

Liter US gal Order numbercan 5 1.3 1615 5953 00can 20 5.3 1615 5954 00barrel 210 55.2 1615 5955 00

Liter US gal Order numbercan 5 1.3 1604 6060 00can 20 5.3 1604 6059 00

- 41 -

OIL LEVEL CHECK

CHECK ENGINE OIL LEVEL

Consult also the Engine Operation Manual for the oilspecifications, viscosity recommendations and oilchange intervals.For intervals, see Preventive maintenance schedulefor the compressor.Check engine oil level according to the instructions inthe Engine Operation Manual and top up with oil ifnecessary.

CHECK COMPRESSOR OIL LEVEL

With the unit standing level, check the level of thecompressor oil. The pointer of the oil level gauge (1)must register in the upper extremity of the greenrange. Add oil if necessary.

Never mix oils of different brands ortypes.Use only non-toxic oils where there is arisk of inhaling delivered air.

Before removing oil filler plug (2),ensure that the pressure is released byopening an air outlet valve.

(2)

(1)

- 42 -

OIL AND OIL FILTER CHANGE

ENGINE OIL AND OIL FILTER CHANGE

For replacing the engine oil filter, see sectionPreventive maintenance schedule for thecompressor.

The quality and the temperature of the oil determinethe oil change interval.The prescribed interval (see section Preventivemaintenance schedule for the compressor) is basedon an oil temperature of up to 100 °C (212 °F) andnormal operating conditions.When operating in high ambient temperatures, in verydusty or high humidity conditions, it is recommendedto change the oil more frequently.

1. Run the compressor until warm. Close the outlet valve(s) and stop the compressor. Wait until the pressure is released through the automatic blow-down valve. Unscrew the oil filler plug (2) one turn. This uncovers a vent hole, which permits any pressure in the system to escape.

2. Drain the oil by removing all relevant drain plugs. Drain plugs are located at the air receiver, compressor element and compressor oil cooler. Catch the oil in a drain pan. Screw out the filler plug to speed up draining. Tighten the plugs after draining.

3. Remove the oil filter (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 (3) registers in the upper extremity of the green range. Take care that no dirt drops into the system. Reinstall and tighten the filler plug.

6. Run the unit at no load for a few minutes to circulate the oil and to evacuate the air trapped in the oil system.

7. Stop the compressor. Let the oil settle for a few minutes. Check that the pressure is released by opening an air outlet valve. Screw out filler plug (2) and add oil until the pointer of the oil level gauge (3) again registers in the upper extremity of the green range. Reinstall and tighten the filler plug.

In this case, contact Atlas Copco.

COMPRESSOR OIL AND OIL FILTER CHANGE

(3)

(1)

(2)

Never add more oil. Overfilling results inoil consumption.

- 43 -

CLEANING COOLERS

Keep the coolers clean to maintain the coolingefficiency.

Remove the baffle (1). Then clean by air jet in reversedirection of normal flow.

Steam cleaning in combination with a cleansing agentmay be applied.

Install the baffle (1).

BATTERY CARE

If the battery is still dry, it must be activated asdescribed in section Activating a dry-chargedbattery.The battery must be in operation within 2 monthsfrom being activated; if not, it needs to be rechargedfirst.

ELECTROLYTE

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

Remove any dirt from the coolers with afibre brush. Never use a wire brush ormetal objects.

(1)

To avoid damaging the coolers, anglebetween jet and coolers should beapprox. 90 °.(do not use jet at max. power)

Protect the electrical and controllingequipment, air filters, etc. againstpenetration of moisture.

Never leave spilled liquids such as fuel,oil, water and cleansing agents in oraround the compressor.

Before handling batteries, read therelevant safety precautions and actaccordingly.

Read the safety instructions carefully.

- 44 -

ACTIVATING A DRY-CHARGED BATTERY

• Take out the battery.• Battery and electrolyte must be at equal

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

reaches 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 bubbles can escape; wait 10 minutes and check the level in each cell once more; if required, add electrolyte.

• Refit plugs and/or cover.• Place the battery in the compressor.

RECHARGING A BATTERY

Before and after charging a battery, always check theelectrolyte level in each cell; if required, top up withdistilled water only. When charging batteries, eachcell must be open, i.e. plugs and/or cover removed.

Apply with preference the slow charging method andadjust the charge current according to the followingrule of thumb:battery capacity in Ah divided by 20 gives safecharging current in Amp.

BATTERY MAINTENANCE

• Keep the battery clean and dry.• Keep the electrolyte level at 10 mm (0.4 in) to

15 mm (0.6 in) above the plates or at the indicated level; top up with distilled water only.

• Keep the terminals and clamps tight, clean, and lightely covered with petroleum jelly.

STORAGE

Run the compressor regularly, e.g. twice a week, untilwarm.Load and unload the compressor a few times tooperate the unloading and regulating components.Close the air outlet valves after stopping.

SERVICE PAKS

A Service Pak is a collection of parts to be used for aspecific maintenance measure.It guarantees that all necessary parts are replaced atthe same time keeping down time to a minimum.The order number of the Service Paks are listed in theAtlas Copco Parts List.

SERVICE KITS

A service kit is a collection of parts to fit a specificrepair or rebuilding task.It guarantees that all necessary parts are replaced atthe same time which improves the uptime of the unit.The order numbers of the Service Kits are listed in theAtlas Copco Parts List.

COMPRESSOR ELEMENT OVERHAUL

When a compressor element is due for overhaul, it isrecommended to have it done by Atlas Copco. Thisguarantees the use of genuine parts and correct toolswith care and precision.

LIABILITY

The manufacturer does not accept any liability for anydamage arising from the use of non-original parts andfor modifications, additions or conversions madewithout the manufacturer’s approval in writing.

Use a commercial automatic batterycharger according to its manufacturer’sinstructions.

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

Contact Atlas Copco.

- 45 -

Adjustments and servicing proceduresADJUSTMENT OF THE CONTINUOUS REGULATING SYSTEM

The working pressure is determined by the tension ofthe spring in the regulating valve (RV). This tensioncan be increased to raise the pressure and decreased tolower it by turning the adjusting wheel clockwise andanti-clockwise respectively.

(AOV)

(RV)

(E)

(SVa)

(SR)

The solenoid valve (SVa) is only presentat units equipped with a generator(XA(S) 137 DDG - XA(S) 300 DD7G).

- 46 -

To adjust the normal working pressure, proceed asfollows:1. Start and warm up the engine (see section

Starting/Stopping).2. With the outlet valves (AOV) closed, loosen the

regulating valve’s lock nut and adjust the regulating valve (RV) until a pressure of X bar(e) is reached (see table).

3. Check the minimum speed of the engine. Adjust minimum speed stop screw if necessary.

4. Open an outlet valve (AOV) just enough to let the engine (E) run at maximum speed. The working pressure must be Y bar(e); adjust if necessary with regulating valve (RV) (see table).

5. Check the engine maximum speed. Adjust the maximum speed by means of adjusting eccentric nut on top of speed regulator (SR).

6. Close the outlet valves (AOV), check that the pressure is between Z1 and Z2 bar(e) (see table). Lock the regulating valve (RV) by fixing the lock nut.

X Y Z1 – Z2XA(S) 137 DD - XA(S) 300 DD7 bar(e) 8.3 7 8.1 – 8.5

psi 120.5 101.5 117.5 – 123.5XA(S) 137 DDG - XA(S) 300 DD7G bar(e) 8.3 7 8.1 – 8.5

psi 120.5 101.5 117.5 – 123.5XAHS 107 DD - XAHS 250 DD7 bar(e) 13.4 12 13.2 – 13.6

psi 194.5 174 191.5 – 197.5

- 47 -

AIR FILTER ENGINE/COMPRESSOR

SERVICING

Always select the service point according to thevacuum indicator or display message. A regularinspection or cleaning as it is sometimes practiced inthe field is more likely to be damaging than useful asthere is a risk that the element will be damaged anddust will gain access to the engine.Atlas Copco always recommends exchangingrather than cleaning the filter element in order toavoid damage and ensure maximum engineprotection.

MAIN PARTS CLEANING THE DUST TRAP

Remove dust daily.To remove dust from the dust trap pinch the vacuatorvalve (6) several times.

CLEANING INSTRUCTIONS FILTER ELEMENT

If element cleaning can not be avoided, care should betaken that the filter element (4) is not washed out.Please note that engine damage can causeconsiderable costs, which makes the cost of a newfilter element seam insignificant.Safety cartridges (3) can not be cleaned but must beexchanged.Please note that a cleaned element will never matchthe service life and performance of a new element.Take the element from the air filter housing (5) (seesection Replacing the air filter element).

The Atlas Copco air filters are speciallydesigned for the application. The use ofnon-genuine air filters may lead tosevere damage of engine and/orcompressor element.Never run the compressor without airfilter element.

1. Snap clips 6. Vacuator valve2. Dust trap cover 7. Vacuum indicator3. Safety cartridge

(option)8. Reset button

4. Filter element 9. Yellow indicator5. Filter housing

(1)

(6)(2) (3)(4) (5)(7)(9)

(8)

- 48 -

In order to clean, position a pipe with an end bent byapprox. 90° on the end of a compressed-air pistol. Thepipe must be long enough to reach the bottom of thefilter element. Carefully blow out the filter elementwith dry compressed air (max. 5 bar (72.5 psi)) fromthe inside to the outside until there is no moredevelopment of dust. The end of the pipe must nottouch the element.

Next carefully examine the element for possibledamage. Never beat or knock the element as this willdamage it and there will be a danger of damage to theengine.Carefully clean the inside of the housing and put theelement in the housing (see section Replacing the airfilter element).

REPLACING THE AIR FILTER ELEMENT New elements must also be inspected for tears orpunctures before installation.Discard the element (4) when damaged.In heavy duty applications it is recommended toinstall a safety cartridge which can be ordered withpart no.: 2914 9311 00.A dirty safety cartridge (3) is an indication of a mal-functioning air filter element. Replace the elementand the safety cartridge in this case.The safety cartridge cannot be cleaned.

1. Release the snap clips (1) and remove the dust trap (2). Clean the trap.

2. Remove the element (4) and the safety cartridge.3. Reassemble in reverse order of dismantling. Make

sure the vacuator valve (6) points down.4. Inspect and tighten all air intake connections.5. Reset the vacuum indicator by pressing the reset

button (5).

(1)

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

- 49 -

AIR RECEIVER

The air receiver (1) is tested according to officialstandards. Regularly have inspections carried out inconformity with local regulations.

SAFETY VALVE

Following checks must be carried out on the safetyvalve (2):• a check of the opening of the lifting gear, twice a

year. This can be done by screwing the cap of the valve anti-clockwise.

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

FUEL SYSTEM

Replacing the filter element1. Unscrew the filter element (1) from the adapter

head.2. Clean the adapter head sealing surface. Lightly oil

the gasket of the new element and screw the latter onto the header until the gasket is properly seated, then tighten with both hands.

3. Check for fuel leaks once the engine has been restarted.

(2)(1)

All adjustments or repairs are to be doneby an authorized representative of thevalve supplier.

(1)

- 50 -

BRAKE (= OPTION) ADJUSTMENT BRAKE SHOE ADJUSTMENT

Check the thickness of the brake lining. Remove bothblack plastic plugs (5), one on each wheel. When thebrake lining has been worn to a thickness of 1 mm(0.039 in) or less, the brake shoes have to be replaced.After inspection and/or replacement re-insert bothplugs.Brake shoe adjustment re-establishes the brakelining-to-drum clearance and compensates for liningwear.

Lift and support the compressor. Make sure that allbrakes are off (overrunbrake and hand brake lever).The brake cables must be free from tension. Lock theswivel cams of the wheel brake from the outside bymeans of a pin ∅ 4 mm (4) through the hole as shownin the Figure.Turn the adjusting bolt (1) clockwise with a wrenchtill the wheel locks up. Center the brake shoes byactuating the parking brake several times.Turn the adjusting bolt anti-clockwise until the wheelis running free in direction of travel (approx. 1 fullturn of the adjusting bolt).Check the position of the equalizer (see sectionBrake cable adjustment, 6) with the parking brakeactuated.Perpendicular position of equalizer = identicalclearance of wheel brakes.Re-adjust the brake shoes, if necessary.To test, slightly apply the parking brake and checkidentical brake torque on left and right side.Remove locking pin (4). Remove clearance frombrake cables. Check all lock nuts (Brake cable adjustment, 2).

Before jacking up the compressor,connect it to a towing vehicle or attach aweight of minimum 50 kg (110 lb) to thetowbar.

1. Adjusting bolt 4. Pin ∅ 4 mm2. Axle 5. Plug3. Brake cable

(1)(5) (3) (2)

(4)

- 51 -

TEST PROCEDURE OF BRAKE CABLE ADJUSTMENT

Correct and wrong position of markings1. Check if the towing eye rod of the overrun brake

mechanism is in the outmost position.2. Check if the adjustable towbar (= option) is in the

actual towing position.3. Apply the hand brake lever.4. Push the compressor a few centimeters backwards

so that the brake lever is automatically pulled further up.

5. Check the position of the arrow marking ”1” at the catch lock in combination with the arrow marking ”2” at the toothed sector, according to A,B,C,D.

2

1

B. Acceptable

C. Too loose; adjust brake cables (Section Brake cable adjustment)

D. Too tight; adjust brake cables (Section Brake cable adjustment)

A. Adjusted correctly

- 52 -

BRAKE CABLE ADJUSTMENT

1. With the towing eye pulled out in the outmost position and the hand brake lever in the downward position (see Figure), loosen the lock nuts (2). Turn adjusting nuts and brake cable nuts (4) clockwise until there is no slack in the brake mechanism.The equalizer (6) must remain perpendicular to main brake cable (5).

2. Apply the hand brake lever several times and repeat the adjustment. Tighten the nuts with their lock nuts (2). Remove the jack and the blocks.

3. Road test the compressor and brake several times. Check brake shoe and brake cable adjustment and if necessary adjust.

Hand brake lever downward - brake not operated1. Brake cable 4. Brake cable nut2. Lock nut 5. Main brake cable3. Adjusting nut 6. Equalizer

(4) (2)(1) (6)

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

- 53 -

Problem solvingIt is assumed that the engine is in good condition andthat there is adequate fuel flow to the filter andinjection equipment.

Make sure that the wires are not damaged and thatthey are clamped tight to their terminals.

An electrical fault must be traced by anelectrician.

Problem Possible faults Corrective actions

1. Starter motor does not crank engine after switching startbutton (S) to ” ”.

a. Low battery output. a. Check electrolyte level and charge battery. If no cells are shorted and battery is discharged, trace cause and correct.

2. Starter motor cranks engine when switching start button (S) to ” ”, but engine does not fire.

a. Low battery output. a. See corrective action 1.

3. Engine fires, but engine stops when releasing start button (S).

a. Alternator drive belt broken or slipping.b. Alternator/regulator defective.

a. Check and correct if necessary.b. Have assembly repaired.

4. Hourmeter (P1) does not count running time.

a. Hourmeter (P1) defective. a. Replace.

5. Engine is running, but shuts down immediately after start button (S) has been released.

a. Start button (S) released too soon.

b. Insufficient engine oil pressure.c. Fuel tank contains insufficient fuel.

a. Release button after engine oil pressure has built up above the minimum allowed level.

b. Stop at once, consult the engine instruction manual.c. Fill fuel tank.

6. Compressor is loaded automatically to full capacity after starting.

a. Air intake throttle valve stuck in opened position.b. Air leaks in regulating system.

a. Check and, if necessary consult Atlas Copco.b. Check hoses and their fittings. Stop leaks; replace

leaking hoses.

7. Unit does not load after pressing the loading button.

a. Regulating valve defective. a. Check and if necessary consult Atlas Copco.

- 54 -

8. Engine does not speed up immediately after compressor loading valve button has been pressed and compressor does not deliver air.

a. Regulating valve defective.b. Air intake throttle valve stuck in closed position.

a. Check and, if necessary consult Atlas Copco.b. Check and, if necessary consult Atlas Copco.

9. Excessive compressor oil consumption. Oil mist being discharged from air outlet valves.

a. Compressor oil level too high. a. Check oil level. Release pressure and drain oil to correct level.

10. Compressor capacity or pressure below normal.

a. Air consumption exceeds capacity of compressor.b. Choked air filter elements.c. Unloading valve not completely open.

a. Check equipment connected.b. Remove and inspect elements.c. Check and, if necessary consult Atlas Copco.

11. Compressor does not unload and engine keeps running at max. speed when closing the air outlet valves, safety valve blows.

a. Regulating valve incorrectly set or defective.b. Air leaks in regulating system.

c. Unloading valve stuck.

a. Check and, if necessary consult Atlas Copco.b. Check hoses and their fittings. Stop leaks and, if

necessary consult Atlas Copco.c. Check and, if necessary consult Atlas Copco.

12. Working pressure rises during operation and causes safety valve to blow.

a. Regulating valve incorrectly set or defective.b. Air leaks in regulating system.

c. Unloading valve stuck.d. Safety valve defective.

a. Check and, if necessary consult Atlas Copco.b. Check hoses and their fittings. Stop leaks and, if

necessary consult Atlas Copco.c. Check and, if necessary consult Atlas Copco.d. Check safety valve; consult Atlas Copco.

13. After working some time, the unit stops through a shutdown switch.

a. Fuel tank contains insufficient fuel.b. Air in fuel system, or insufficient fuel supply.c. Engine oil pressure too low.d. Engine temperature too high.e. Compressor temperature too high.f. Low coolant level.

a. Fill fuel tank.b. Check filters and hoses for leaks, dirt and bends.c. Refer to the engine instruction manual.d. See corrective actions 15.e. See corrective actions 16.f. Top up cooling system.

14. Air and oil mist expelles from air filters immediately after stopping.

a. Unloader valve jammed.b. Wrong oil type (without foam-retarding additives).

a. Check and, if necessary consult Atlas Copco.b. Consult Atlas Copco.

Problem Possible faults Corrective actions

- 55 -

Alternator precautions1. Never reverse the polarity of the battery or the

alternator.2. Never break any alternator or battery connections

while the engine is running.3. When recharging the battery, disconnect it from

the alternator. Before using booster cables to start the engine, be sure of the polarity and connect the batteries correctly.

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

15. Engine overheating. a. Insufficient engine cooling.b. Engine oil cooler clogged externally.

a. Relocate compressor.b. Clean engine oil cooler. Refer to section Cleaning

coolers.

16. Compressor overheating. a. Insufficient compressor cooling.

b. Oil cooler clogged externally.c. Oil level too low.

a. Locate compressor away from walls; when banked with other compressors, leave space between them.

b. Clean oil cooler. Refer to section Cleaning coolers.c. Check oil level. Top up with recommended oil.

17. After working for some time, the unit stops for no apparent reason.

a. Air in fuel system, or insufficient fuel supply. a. Check filters and hoses for leaks, dirt and bends.

Problem Possible faults Corrective actions

- 56 -

Available options

A. These units meet your local safety regulations and are available with overrun and parking brakes.

B. Reflectors and lights for safety on the road.C. Quality air through the aftercooler, reheater and fine filters.

Vessel type: EUROASME

Towbar: Adjustable with brakes (A)Fixed with brakes (A)Fixed without brakes

Without towbar: Support (without undercarriage)Towing eyes: Atlas Copco

DINBallItalianGBNATOAC (France)

Towbar support: Support legJockey wheel

Road signalisation: Full (B)Safety: Wheel chocks

Safety cartridgeRefinery equipment: Spark arrestor

Inlet shut down valve

Air quality equipment: Aftercooler + water separatorAftercooler + water separator + fine filter PDAftercooler + water separator + fine filter DD + PDAftercooler + water separator + fine filter PD + reheater (C)Aftercooler + water separator + fine filter DD + PD + reheater (C)Aftercooler + water separator + reheaterLubricator on 7 bar units

Cold start: -20 °C (-4 °F)Customer colour: Single

DoubleTriple

- 57 -

Technical specificationsTORQUE VALUES

FOR GENERAL APPLICATIONS

The following tables list the recommended torques applied for general applicationsat assembly of the compressor.

For hexagon screws and nuts with strength grade 8.8

For hexagon screws and nuts with strength grade 12.9

FOR IMPORTANT ASSEMBLIES

Thread size Torque value (Nm / lbf.ft) M6 9 (6.64)M8 23 (16.97)M10 46 (34.69M12 80 (59.04)M14 125 (92.25)M16 205 (151.29)

Thread size Torque value (Nm / lbf.ft) M6 15 (11.07)M8 39 (28.78)M10 78 (57.56)M12 135 (99.63)M14 210 (154.98)M16 345 (254.61)

Assemblies Torque value (Nm / lbf.ft)Wheel nuts 120 (88.56) +/- 15Bolts, axle/beams 205 (151.29) +/- 20Bolts, towbar/axle 80 (59.04) +/- 10Bolts, towbar/bottom 205 (151.29) +/- 20Bolts, towing eye/towbar 80 (59.04) +/- 10Bolts, lifting eye/flywheel housing 205 (151.29) + 20Bolts, engine/drive housing (M12) 80 (59.04) +/- 10Bolts, engine/drive housing (M14) 125 (92.25) +/- 10Bolts, compressor element/drive housing

80 (59.04) +/- 5

Safety switches 35 (25.83) +/- 5Joints adjustable towbar (M24) 275 (202.95) +/- 25Joints adjustable towbar (M32) 375 (276.75) +/- 25

Secure the drain cock and tank cap of the fuel tank handtight.

- 58 -

SETTINGS OF SHUTDOWN SWITCHES AND SAFETY VALVES

Designation XA(S) 137 DD - XA(S) 300 DD7

XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

Engine oil pressure bar(e) 6 6 6psi 87 87 87

Engine oil temperature °C 120 120 120°F 248 248 248

Compressor temperature °C 120 120 120°F 248 248 248

Safety valve opening pressure- EC type bar(e) 10 10 15- ASME type psi 150 150 218

- 59 -

COMPRESSOR/ENGINE/GENERATOR SPECIFICATIONS

REFERENCE CONDITIONS

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

Designation XA(S) 137 DD - XA(S) 300 DD7

XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

230/400 V (3 phase)Absolute inlet pressure bar(e) 1 1 1

psi 14.5 14.5 14.5Relative air humidity % 0 0 0Air inlet temperature °C 20 20 20

°F 68 68 68Nominal effective working pressure bar(e) 7 7 12

psi 102 102 174

- 60 -

LIMITATIONS

1) Compressor: PAROIL S i.s.o. PAROIL MPAROIL 5W40 i.s.o. 15W40

Designation XA(S) 137 DD - XA(S) 300 DD7

XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

230/400 V (3 phase)Minimum effective receiver pressure bar(e) 4 4 4

psi 58 58 58Maximum effective receiver pressure, compressor unloaded

bar(e) 8.5 8.5 13.5psi 123 123 196

Maximum ambient temperature at sealevel EC

standard °C 48 48 49°F 118 118 120

aftercooler option

°C 40 40 41°F 104 104 106

Maximum ambient temperature at sealevel NON EC

standard °C 53 53 53°F 127 127 127

aftercooler option

°C 45 45 45°F 113 113 113

Minimum starting temperature °C - 10 - 10 - 10°F 14 14 14

Minimum starting temperature, with coldstart equipment 1) °C - 20 - 20 - 20°F - 4 - 4 - 4

Altitude capability see curves

- 61 -

Performance dataMax. allowable working pressure as a function of altitude and ambient temperature.

6000

5000

4000

3000

2000

1000

0

14 32 50 68 86 104 122

-10,0 0,0 10,0 20,0 30,0 40,0 50,0

16.405

13.124

9.843

6.562

3.281

0 ft

07 bar(e)102 psi

27/jul/07

XAS 137 Dd

XAS 300 DD7

ALT

ITU

DE

IN M

ALT

ITU

DE

IN F

T

TEMPERATURE IN °F

TEMPERATURE IN °C

6000

5000

4000

3000

2000

1000

0

14 32 50 68 86 104 122

-10,0 0,0 10,0 20,0 30,0 40,0 50,0

16.405

13.124

9.843

6.562

3.281

0 ft

07 bar(e)

3/aug/07

XAS 137 DdG

XAS 300 DD7G

102 psi

ALT

ITU

DE

IN M

ALT

ITU

DE

IN F

T

TEMPERATURE IN °F

TEMPERATURE IN °C

6000

5000

4000

3000

2000

1000

0

14 32 50 68 86 104 122

-10,0 0,0 10,0 20,0 30,0 40,0 50,0

16.405

13.124

9.843

6.562

3.281

0 ft

12 bar(e)174 psi

27/jul/07

XAHS 107 Dd

XAHS 250 DD7

ALT

ITU

DE

IN M

ALT

ITU

DE

IN F

T

TEMPERATURE IN °F

TEMPERATURE IN °C

- 62 -

PERFORMANCE DATA

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

Designation XA(S) 137 DD - XA(S) 300 DD7

XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

230/400 V (3 phase)Engine shaft speed, normal and maximum r/min 2400 2400 2400Engine shaft speed, compressor unloaded r/min 1800 1700 1800Engine shaft speed, generator at maximum load r/min - 2400 -Free air delivery 1)standard EC l/s 125 96 93

cfm 265 203 197NON EC l/s 127 98 95

cfm 269 208 201with aftercooler EC l/s 120 92 88

cfm 254 195 186NON EC l/s 122 94 90

cfm 259 199 191

- 63 -

Fuel consumption

Designation XA(S) 137 DD - XA(S) 300 DD7

XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

230/400 V (3 phase)at 100% FAD kg/h 11.6 n.a. 11.6

lb/h 25.6 n.a. 25.6at 75% FAD kg/h 9.7 n.a. 9.7

lb/h 21.4 n.a. 21.4at 50% FAD kg/h 8.0 n.a. 8.0

lb/h 17.6 n.a. 17.6at 25% FAD kg/h 5.7 n.a. 5.7

lb/h 12.6 n.a. 12.6at unload kg/h 5.0 n.a. 5.0

lb/h 11.0 n.a. 11.0Specific fuel consumptionstandard EC g/m3 25.8 n.a. 34.6

lb/103 cu.ft 1.61 n.a. 2.16NON EC g/m3 25.4 n.a. 33.9

lb/103 cu.ft 1.58 n.a. 2.12with aftercooler EC g/m3 26.9 n.a. 36.6

lb/103 cu.ft 1.68 n.a. 2.29NON EC g/m3 26.4 n.a. 35.8

lb/103 cu.ft 1.65 n.a. 2.24

- 64 -

1) Free Air Delivery (volume flow rate) is measured according to ISO 1217 ed.3 1996 annex DTolerance:• +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm)• +/- 4% 250 l/s (530 cfm) < FADThe international standard ISO 1217 corresponds to following national standards:• British BSI 1571 part 1• German DIN 1945 Part 1• Swedish SS-ISO 1217• American ANSI PTC9

Designation XA(S) 137 DD - XA(S) 300 DD7

XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

230/400 V (3 phase)Typical oil content of compressed air mg/m3 < 5 < 5 < 5

oz/103 cft < 0.005 < 0.005 < 0.005Engine oil consumption (maximum) g/h 58 58 58

oz/h 2.05 2.05 2.05Compressed air temperature at outlet valves

standard °C 90 90 90°F 194 194 194

with aftercooler

°C 30 30°F 86 86

Sound pressure level (Lp), measured according to ISO 2151/EPA under free field conditions at 7 m distance

ISO 2151 dB(A) 71 71 71EPA dB(A) 76 76 76

Sound power level (Lw) complies with 2000/14/EC

ISO 2151 dB(A) 99 99 99

Sound power level (Lw) complies with 84/533/EEC and 85/406/EEC limits

EPA dB(A) 104 104 104

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DESIGN DATA

Compressor

Engine

1) With filter change.

DesignationNumber of compression stages 1

Designation XA(S) 137 DD - XA(S) 300 DD7XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

Make DeutzType BF4M2011Coolant OilNumber of cylinders 4Bore mm 94

in 3.70Stroke mm 112

in 4.41Swept volume l 3.1

cu.in 189.7Output according to DIN 6271 at normal shaft speed

kW 58BHP 77.8

- Load factor % 50

Designation XA(S) 137 DD - XA(S) 300 DD7XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

Capacity of oil sump:- Initial fill l 11

US gal 2.91- Refill (max.) 1) l 6.5

US gal 1.72Capacity of cooling system l -

US gal -

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Unit

1) Air required for engine and compressor cooling, for combustion and forcompression.

Unit dimensions

Designation XA(S) 137 DD - XA(S) 300 DD7XA(S) 137 DDG - XA(S) 300 DD7G

XAHS 107 DD - XAHS 250 DD7

Capacity of compressor oil system

l 13US gal 3.43

Net capacity of air receiver l 35US gal 9.25

Capacity of fuel tank l 130US gal 34

Air volume at inlet grating (approx.) 1)

m3/s 2.5cfm 88

with brakes towbarfixed adjustable

Length mm 3768 4278in 148.3 168.4

Width mm 1676 1676in 66 66

Height mm 1479 1479in 58.2 58.2

Weight (ready-to-operate) kg 1500 1450lb 3306.9 3196.7

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DESIGN DATA FOR GENERATOR

Alternator

Circuit-breaker

Electrical power circuit

Fault current protection

DesignationStandard IEC 34-1Make MECC ALTEModel TR-2 ---/2Rated output kVA 12Degree of protection IP 23Insulation- stator class H- rotor class HNumber of phases 3Number of leads 6

Designation 230/400V (3 phase)Number of poles 4Rated current In 1ph/3ph A 16/16Thermal release It 1ph/3ph A 16/32Magnetic release Im A 3..5 In

Designation 230/400V (3 phase)Rated continuous active power COP kW 9.6Rated power factor (lagging) 0.8Rated continuous apparent power 3ph COP

kVA 12

Rated voltage 3ph line to line V 400Rated current 3ph A 17Rated continuous apparent power 1ph COP

kVA

Rated voltage 1ph line to line V 230Rated current 1ph A 16Frequency droop % < 5

Designation 230/400V (3 phase)Insulation resistance kOhm 13

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Data plate1 Company code2 Product code3 Unit serial number4 Name of the manufacturer5 EEC or national type approval number6 Vehicle identification number7 A Maximum permitted total weight of the

vehicleB Maximum permitted axle loadC Maximum permitted load on the towing eye

8 Model9 Working pressure10 Speed11 Engine power12 Manufacturing year13 CE mark in accordance with Machine Directive

89/392 EC14 Register number or number of notified body

(1) (2) (3)

(4)(5)(6)

(7)

(8)(9)

(10)(11)

(12)

(14)(13)

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DisposalGENERAL

When developing products and services, Atlas Copcotries to understand, address, and minimize thenegative environmental effects that the products andservices may have, when being manufactured,distributed, and used, as well as at their disposal.Recycling and disposal policy are part of thedevelopment of all Atlas Copco products. AtlasCopco company standards determine strictrequirements.Selecting materials the substantial recyclability, thedisassembly possibilities and the separability ofmaterials and assemblies are considered as well as theenvironmental perils and dangers to health during therecycling and disposal of the unavoidable rates of notrecyclable materials.Your Atlas Copco compressor consists for the mostpart of metallic materials, that can be remelted insteelworks and smelting works and that is thereforealmost infinite recyclable. The plastic used islabelled; sorting and fractioning of the materials forrecycling in the future is forseen.

DISPOSAL OF MATERIALS

Dispose contaminated substances and materialseparately, according to local applicableenvironmental legislations.Before dismantling a machine at the end of itsoperating lifetime drain all fluids and dispose ofaccording the applicable local disposal regulations. Remove the batteries. Do not throw batteries into thefire (explosion risk) or into the residual waste.Separate the machine into metal, electronics, wiring,hoses, insulation and plastic parts. Dispose all components according to the applicabledisposal regulations.Remove spilled fluid mechanically; pick up the restwith absorbing agent (for example sand, sawdust) anddispose it according the applicable local disposalregulations. Do not drain into the sewage system orsurface water.

This concept can only succeed with yourhelp. Support us by disposingprofessionally. By assuring a correctdisposal of the product you help toprevent possible negative consequencesfor environment and health, that canoccur with an inappropriate wastehandling.Recycling and re-usage of material helpsto preserve natural resources.

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Maintenance Log

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

Serial number........................................................................................ ................................................................................................................

Service hours Maintenance action Date By initials

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Notes

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Notes

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Notes

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