2954 2140 03_XA(H)S37-57 DD_EN

XAHS 37 DD - XAHS 70 DD7 Engine DeutzXAS 47 DD - XAS 90 DD7 D2011L02XAS 57 DD - XAS 110 DD7

Instruction Manualfor Portable CompressorsEnglish

ATLAS COPCO - PORTABLE AIR DIVISIONwww.atlascopco.com

Original instructions

Printed matter N°2954 2140 03

10/2010

Instruction Manualfor Portable Compressors

XAHS 37 DD - XAHS 70 DD7XAS 47 DD - XAS 90 DD7XAS 57 DD - XAS 110 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 from modifications, additions orconversions made without the manufacturer's approval in writing.Neglecting maintenance or making changes to the setup of the machine can result in major hazards, includingfire risk.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 2010, 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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PrefaceFollow the instructions in this booklet and weguarantee you years of troublefree operation. It is asolid, safe and reliable machine, built according tothe latest technology.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 (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 Safety pictograms used .............................. 142.2 General description .................................... 14

3 Main Parts................................................. 163.1 Compressor regulating system ................... 183.1.1 Overview................................................ 183.1.2 Air flow.................................................. 203.1.3 Oil system .............................................. 213.1.4 Continuous pneumatic regulating

system .................................................... 223.2 Electric system ........................................... 243.2.1 Circuit diagram (standard)

(9822 0991 32)....................................... 243.2.2 Generator DDG 110V

without automatic control system .......... 283.2.3 Generator DDG 110V

with automatic control system ............... 303.2.4 Generator DDG IT 230/400V

without automatic control system .......... 323.2.5 Generator DDG IT 230/400V

with automatic control system ............... 34

3.2.6 Generator DDG IT 230V, 6 kVA .......... 363.2.7 Circuit diagram refinary equipment

9822 0909 00 (all types) ........................ 383.3 Markings and information labels ............... 40

4 Operating instructions ............................. 414.1 Parking, towing and lifting instructions..... 414.1.1 Parking instructions ............................... 414.1.2 Towing instructions ............................... 424.1.3 Height adjustment .................................. 434.1.4 Spillage-Free Instruction ....................... 434.1.5 Instructions ball coupling (option)......... 444.1.6 Lifting instructions................................. 444.1.7 Diesel particle filter (option) ................. 454.1.8 Anti-Frost Device (option) .................... 454.2 Starting / Stopping ..................................... 464.3 Before starting............................................ 464.3.1 Starting procedure

(with cold start; option) ......................... 474.3.2 Starting procedure

(without cold start)................................. 494.3.3 During operation .................................... 514.3.4 Stopping procedure ................................ 514.3.5 Fault situations and protective devices .. 514.4 Functional description of generator

(option)....................................................... 524.4.1 DDG 110V without automatic

control system........................................ 524.4.2 DDG 110V with automatic

control system (option) .......................... 534.4.3 DDG 230/400V and 230V - 3ph

without automatic control system.......... 544.4.4 DDG 230/400V and 230V - 3ph

with automatic control system (option) . 55

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5 Maintenance.............................................. 575.1 Preventive maintenance schedule............... 575.2 Use of service paks..................................... 575.3 Maintenance schedule compressor............. 575.4 Diesel particle filter .................................... 605.5 Maintenance schedule undercarriage ......... 615.6 Lubrication oils........................................... 625.7 Oil specifications........................................ 635.7.1 Compressor oil ....................................... 635.8 Oil level check............................................ 645.8.1 Check engine oil level............................ 645.8.2 Check compressor oil level .................... 645.9 Oil and oil filter change.............................. 655.9.1 Engine oil and oil filter change .............. 655.9.2 Compressor oil and oil filter change ...... 655.10 Compressor Oil Flushing Procedure .......... 665.11 Cleaning coolers ......................................... 675.12 Cleaning fuel tank ...................................... 675.13 Cleaning hardhat......................................... 685.14 Battery care................................................. 685.14.1 Electrolyte .............................................. 685.14.2 Activating a dry-charged battery............ 685.14.3 Recharging a battery .............................. 685.14.4 Battery maintenance............................... 685.15 Changing tyres............................................ 695.16 Storage........................................................ 695.17 Service paks................................................ 695.18 Service kits ................................................. 695.19 Compressor element overhaul .................... 695.20 Liability ...................................................... 69

6 Adjustments and servicing procedures .. 706.1 Adjustment of the continuous pneumatic

regulating system ....................................... 706.2 Air filter engine/compressor ...................... 726.2.1 Cleaning the dust trap ............................ 726.2.2 Recommendations.................................. 726.2.3 Replacing the air filter element.............. 726.3 Air receiver................................................. 736.4 Drive Belt ................................................... 736.5 Safety valve ................................................ 736.6 Fuel system................................................. 736.7 Brake (= option) adjustment....................... 746.7.1 Brake shoe adjustment ........................... 746.7.2 Brake cable adjustment .......................... 746.7.3 Test procedure brake cable

adjustment .............................................. 756.8 Wheels........................................................ 766.8.1 Wheel check........................................... 766.8.2 Lubrication............................................. 766.8.3 Wheel bolts check .................................. 776.8.4 Wheel bearing adjustment...................... 786.9 Towbar and overrun brake ......................... 796.9.1 Towbar and overrun brake check........... 796.9.2 Lubrication............................................. 80

7 Problem solving ........................................ 82

8 Available options ...................................... 87

9 Technical specifications ........................... 889.1 Torque values ............................................. 889.1.1 General torque values ............................ 889.1.2 Critical torque values ............................. 88

9.2 Settings of shutdown switches andsafety valves............................................... 89

9.3 Compressor / engine specifications............ 909.3.1 Reference conditions ............................. 909.3.2 Limitations............................................. 919.3.3 Altitude unit performance curves .......... 929.3.4 Performance data ................................... 949.3.5 Design data ............................................ 959.3.6 Design data for generator....................... 97

10 Dataplate ................................................. 100

11 Disposal ................................................... 10111.1 General ..................................................... 10111.2 Disposal of materials................................ 101

12 Maintenance Log.................................... 102

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Safety precautions (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 Preventive maintenance schedule.

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.

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.

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

17bPortable 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-airsystem, fit an appropriate non-return valve (checkvalve) between compressor outlet and theconnected sand-blasting or compressed-airsystem. Observe the right mounting position/direction.

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

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

13 Never refill fuel while the unit is running, unlessotherwise stated in the Atlas Copco InstructionBook (AIB). Keep fuel away from hot parts suchas air outlet pipes or the engine exhaust. Do notsmoke when fuelling. When fuelling from anautomatic pump, an earthing cable should beconnected to the unit to discharge staticelectricity. Never spill nor leave oil, fuel, coolantor cleansing agent in or around the unit.

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

15 Periodically carry out maintenance worksaccording to the maintenance schedule.

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

17 Noise, even at reasonable levels, can causeirritation and disturbance which, over a longperiod of time, may cause severe injuries to the

nervous system of human beings. When the soundpressure level, at any point where personnelnormally has to attend, is:- below 70 dB(A): no action needs to be taken,- above 70 dB(A): noise-protective devices

should be provided for people continuouslybeing present in the room,

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

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

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

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

18 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.

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21 When using compressed air or inert gas to cleandown equipment, do so with caution and use theappropriate protection, at least safety glasses, forthe operator as well as for any bystander. Do notapply compressed air or inert gas to your skin ordirect an air or gas stream at people. Never use itto clean dirt from your clothes.

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

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

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

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

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

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 a

qualified 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 Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.

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

35 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.

36 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.

37 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 batteryshall be disconnected and removed or theterminals covered by insulating caps. Onelectrically driven units the main switch shall belocked in open position and the fuses shall betaken out. A warning sign bearing a legend suchas ”work in progress; do not supply voltage” shallbe attached to the fuse box or main switch.

4 Before dismantling any pressurized component,the compressor or equipment shall be effectivelyisolated from all sources of pressure and the entiresystem shall be relieved of pressure. Do not relyon non-return valves (check valves) to isolatepressure systems. In addition, a warning sign

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bearing a legend such as ”work in progress; donot open” shall be attached to each of the outletvalves.

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

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

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

8 Take safety precautions against toxic vapours ofcleaning liquids.

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

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

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

12 Support the 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 the

selected 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.Submit the generator to a testrun, check that theAC power performance is correct.

TOOL APPLICATIONS SAFETY

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

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SPECIFIC SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

separator and is designed to hold compressed airfor the following application:- pressure vessel for compressor,- medium AIR/OIL,and operates as detailed on the data plate of 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).

2 The pressure vessel is only to be used for theapplications as specified above and in accordancewith the technical specifications. Safety reasonsprohibit any other applications.

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

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

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

6 Draining of condensate shall be performed dailywhen vessel is in use.

7 Installation, design and connections should not bechanged.

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

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

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Leading particularsSAFETY PICTOGRAMS USED GENERAL DESCRIPTION

General view metal canopy

The compressors type XAHS 37 DD - XAHS 70DD7, XAS 47 DD - XAS 90 DD7 and XAS 57 DD -XAS 110 DD7 are silenced, single-stage, oil-injectedscrew compressors, built for a nominal effectiveworking pressure, ranging from 7 bar (102 psi) up to12 bar (174 psi) (see chapter Technicalspecifications).The compressor is available with metal or PE canopy(HardHat).

General view HardHat

EngineThe compressor is driven by an oil-cooled dieselengine. The engine’s power is transmitted to the compressorthrough a heavy-duty drive belt.

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

This symbol is followed bysupplementary information.

- 14 -

Compressor elementThe 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 through the oilseparator element.The vessel is provided with an oil level indicator.

RegulationThe compressor is provided with a continuouspneumatic regulating system and a blow-down valvewhich is integrated in the unloader assembly. Thevalve is closed during operation by outlet pressure ofthe compressor element and opens by air receiverpressure when the compressor is stopped.When the air consumption increases, the air receiverpressure will decrease and vice versa.This 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.

Cooling systemEngine and compressor are provided with an oilcooler.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 axlesThe compressor/engine unit is supported by rubberbuffers in the frame. The standard unit has a noneadjustable towbar with support leg and one of thefollowing towing eyes AC, DIN, ball, ITA, GB orNATO.As an option the unit can be equipped with anadjustable towbar, a jockey wheel and/or overrunparking brake (for options see chapter Availableoptions).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 and ahood for maintenance and service operations. Thebodywork is internally lined with sound-absorbingmaterial.

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 plate (D)showing the product code, the unit number and theworking pressure (see chapter Dataplate).

Serial numberThe serial number is located on the right-hand frontside of the frame.

Generator (option for XAS 47 DD - XAS 90 DD7)The built-in generator is driven by a multi V-beltdrive. The generated current can be drawn via 3sockets (see chapter Technical specifications).The compressor and the generator of the XAS 47DDG - XAS 90 DD7G / DDG IT may be usedsimultaneously.As an option the generator can be equipped with anautomatic control system to save fuel when noelectric power is used.

- 15 -

Main Parts

(SV)

(A)

(VI)(AR)(RV)

(FP)

(G)

(OLG)

(AOV)

(CP)

(DB) (AF)(VV)

(FF)(FU)

(CE)

(F)

(EP)

(FT)

(D)

(SN)

(FCeo)

(FCft)

(DPec)

(DSe)

(OFe)

(OFce)

(JW)

(BH)

(TB)

(H)

(DPft)

(S)(E)

(AFD)

(CPG)

- 16 -

Reference NameA AlternatorAF Air FilterAFD Anti-Frost Device (option)AOV Air Outlet ValvesAR Air ReceiverBH Brake HandleCE Compressor ElementCP Control Panel (compressor)CPG Control Panel (generator), (option)D Data PlateDB Drive BeltDPec Drain Plug Engine Oil CoolerDSe Engine Oil Level DipstickE EngineEP Exhaust PipeF FanFCeo Filler Cap (engine oil)FCft Filler Cap (fuel tank)FF Fuel FilterFP Filler Plug (compressor oil)

Reference NameFT Fuel TankFU Fuel PumpG Generator (option)H HoodJW Jockey wheelOFce Oil Filter (compressor element)OFe Oil Filter (engine)OLG Oil Level Gauge (compressor

element)RV Regulating ValveS Starting MotorSN Serial NumberSV Safety ValveTB TowbarVI Vacuum IndicatorVV Vacuator Valve

- 17 -

COMPRESSOR REGULATING SYSTEM

OVERVIEW

(FP)

(SR)

(RV)

(FR)

(OS)

(AR)

(AOV)

(FN)

(DP)

(SV)

(OLG)

(PG)

(SL)

(OF)

(UA)

(UV)

(VH)(BDV)(DB)(CV)

(CE)(DP)

(TS)

(SL)

(OCce)

(AF)

(VV)

(FP)

(RV)

(FR)(SV)

(SVsr)

(PG)

(SL)

(BDV)(CV)

(VI)

(E)

(F)

With generator

Without generator

- 18 -

Reference NameAF Air FilterAOV Air Outlet ValvesAR Air ReceiverBDV Blow Down ValveCE Compressor ElementCV Check ValveDB Drive BeltDP Drain PlugE EngineF FanFN Flow NozzleFP Filler PlugFR Flow RestrictorOCce Oil Cooler (compressor element)OF Oil FilterOLG Oil Level GaugeOS Oil Separator

Reference NamePG Pressure GaugeRV Regulating ValveSL Scavenge LineSR Speed RegulatorSV Safety ValveSVsr Solenoid Valve (Speed regulator)TS Temperature SwitchUA Unloader AssemblyUV Unloader ValveVH Vent HoleVI Vacuum IndicatorVV Vacuator Valve

- 19 -

AIR FLOW

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 flow nozzle (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.

(OS)

(AR)

(FN)

(PG)

(BDV)(CV)

(CE)

(TS)

(AF)

- 20 -

OIL SYSTEM

The lower part of the air receiver (AR) serves as oiltank.Air pressure forces the oil from the air receiver/oilseparator (AR/OS) through the oil cooler (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 a scavenging line (SL), which isprovided with a flow restrictor (FR).The oil filter by-pass valve opens when the pressuredrop over the filter is above normal because of aclogged filter. The oil then by-passes the filterwithout being filtered. For this reason, the oil filtermust be replaced at regular intervals (see sectionPreventive maintenance schedule).When cold start equipment is installed, a thermostaticvalve will bypass the compressor oil (oil will not passthrough oil cooler OCce), until the workingtemperature is reached.

(FR)

(OS)

(AR)

(SL)

(OF)

(CE)

(OCce)

- 21 -

CONTINUOUS PNEUMATIC REGULATING SYSTEM

(SR)

(RV)

(AR)

(UA)

(UV)

(VH)

(CE)

(SVsr)With generator

Without generator

- 22 -

The compressor is provided with a continuouspneumatic regulating system. This system is providedwith a blow-down valve which is integrated in theunloader assembly (UA). The valve is closed duringoperation by outlet pressure of the compressorelement and opens by air receiver pressure 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.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 unloadervalve (UV) gradually opens the air intake and thespeed 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 the atmosphere, andany condensate discharged, through the vent holes(VH).GeneratorWhen the generator is switched on, the solenoid valve(SVsr) via the speed regulator (SR) controls theengine and allows it to reach maximum speed (thenormal control system is switched off).

- 23 -

ELECTRIC SYSTEM

CIRCUIT DIAGRAM (STANDARD) (9822 0991 32)

- 24 -

(Coldstart Option)

Reference NameF1 Circuit Breaker (10 A)G1 AlternatorG2 BatteryH1 Temperature Alarm LampH2 General Alarm LampK0 Starter Solenoid (part of M1)K1 Relay Temperature AlarmK2 Relay Temperature Alarm HoldK3 Override Start RelayK4 RelayK5 Relay Heater Plug (coldstart

option)M1 Starter MotorN1 Starter Protection RelayP1 HourmeterR1 Heater Plug (coldstart option)S1 Contact Switch (Off-On-

Override-start)S2 Temperature Switch EngineS3 Oil Pressure Switch EngineS4 Lamptest SwitchS5 Temperature Switch CompressorS6 Coldstart Switch (coldstart

option)V1 Diode

Reference NameV2 DiodeX1 ConnectorX3 Auxiliary ConnectionY1 Fuel Solenoid Valve

The compressor is equipped with a negative earthedsystem.

- 25 -

Operation of the electric circuit in detail

Start switch S1 position 1:Line 2 on 12V contact K3 closed (30-87a), lamp H2is on. K4 excites contact K4 (30-87). Thermocontactelement S5 normally closed, K1 excites contact K1(30-87).

Use of lamp test:Start switch S1 position 1 press lamp test S4, acrossK3 and line 9 lamp H1 and relay K2 are excited. Afterreleasing lamp test button S4, lamp H1 remains on, S4taken over by contact K2.

Start switch S1 position 2:Line 3 on 12V (overwrite function) hourmeter P1 andfuel solenoid Y1 excited. Thermocontact engine S2normally closed, oil pressure contact S3 open.

Start switch S1 position 3:Start relay K0 is excited and starter motor is running,engine builds up oil pressure and oil pressure contactS3 closes. K3 excited and contact K3 changes over to(30-87). Relay K2 no longer excited, contact K2opens, lamp H1 goes out. Alternator also commencessupplying voltage and K4 is no longer excited andcontact K4 changes over to (30-87a). Lamp H2 goesout, one can release start switch S1 and it returns toposition 1. Exciting the safety devices occurs nolonger across line 3 but across line 2 to line 4 and thisway to line 3.

(K1) (K2)

(K3) (K4)

- 26 -

Engine is running normally:Oil pressure contact S3 opens, K3 no longer excited.K3 changes over (30-87a), engine cuts out becausefuel solenoid Y1 no longer excited and lamp H2 goeson simultaneously. Thermocontact S2 opens, K3 no longer excited. K3changes over (30-87a), engine cuts out because fuelsolenoid Y1 no longer excited and lamp H2 goes onsimultaneously.Thermocontact S5 opens, K1 no longer excited.Contact K1 changes over (30-87a). K3 no longerexcited. K3 changes over (30-87a), engine cuts outbecause fuel solenoid Y1 no longer excited and lampH2 and H1 go on simultaneously. Take-over relay K2is excited simultaneously with H1 and contact K2closes (30-87).Thermocontact S5 cools off and closes, K1 excitedagain and contact K1 changes over (30-87).However, lamp H1 remains on across line 9 andcontact K2 (30-87).A fault in the alternator part causes terminal D+ to goto 0V and K4 to be excited. Contact K4 changes overto (30-87), engine cuts out because fuel solenoid Y1no longer excited and lamp H2 goes onsimultaneously.N1 prevents the starter motor from being used whenthe engine is running.

- 27 -

GENERATOR DDG 110V WITHOUT AUTOMATIC CONTROL SYSTEM

Circuit diagram 9822 1055 27 (Not on HardHat)

X3

3L1

3L2

L2L1

16A

e54c0c0

X2

L2L1

16A

H3A1

A2

K5

52 51

S7

P

B

R Y2

K512

34

V W

V1

W1

1L1

1L2

2L1

2L2

50A

Q1

b3

G

G3V W

14

12

3

13

b6 b6

12

b6

b3

b6

b3

13

1212

b3

13

35

34

e54c0c0e54e0e0

f0f0

f0f0

e0e0

e0e0e0e0

e54

56

78

X1

L2L1

32A

32A

Q2

16A

Q3

16A

Q4

13b3

L1

L2

b6

12

b3

I n30mA

40msec

4567

10

11

1

3

N13

D1

e0

e0

1234

T13

EARTHING PIN

To Circuit diagram9822 0797 01

Reference NameD1 DiodeG3 GeneratorH3 Lamp (Power ON)K5 ContactorN13 Earth faultcurrent relayQ1 Main circuit breaker 2-poleQ2 Circuit breaker 2-poleQ3 Circuit breaker 2-poleQ4 Circuit breaker 2-poleS7 Switch (Generator-compressor)T13 Current transformer for N13X1 Socket outletX2 Socket outletX3 Socket outletY2 Solenoid valve (Generator action)

The compressor is equipped with a negative earthedsystem.For location of relais K1, K2, K3, K4, see paragraphElectric system.

- 28 -

Operation of the electric circuit in detailCompressor function:See Circuit diagram (standard) (9822 0991 32).

Generator function: Turn switch S7 to position 1. The solenoid valve Y2via the speed regulator controls the motor and allowsit to reach maximum speed (the normal controlsystem is switched off). Lamp H3 is activated andsockets X1, X2, X3 are under tension. The generator can be switched off by turning switchS7 to position 0. An insulation fault is detected when a leakage currentis flowing. Contactor K5 will no longer be exitedthrough the earth faultcurrent relay N13.

- 29 -

GENERATOR DDG 110V WITH AUTOMATIC CONTROL SYSTEM


X3

3L1

3L2

L2L116A

e54c0c0

X2

L2L116A

H3A1

A2

K5

52 51

S7

P

B

R Y2

K512

34

V W

V1

W1

1L1

1L2

2L1

2L2

50A

Q1

G

G3V W

14

12

3

b6

b6

12

b6

b3

b6

b313

12

12

b3

13

35

34

e54c0c0e54e0e0

f0f0

f0f0

e0e0

e0e0e0e0

e54

56

78

X1

L2L132A

32A

Q2

16A

Q3

16A

Q4

13b3

13b3

34S8

H4

A1

A2

K8

A1

A2

K7

b6

12

b6

12

b6

9

b3

b3

b3

b3b3b3 b6

b6b3

b3

11

15

L1

L2

b6

12

b3

I n30mA

40msec

4567

10

11

1

3

N13

D1

e0

e0

1234

T13

EARTHING PIN

2 134567

E1

To Circuitdiagram

9822 0797 01

Reference NameD1 DiodeE1 EcologiserG3 GeneratorH3 Lamp (Power ON)H4 Lamp automatic control systemK5 ContactorK7 Time relaisK8 Time relaisN13 Earth faultcurrent relayQ1 Main circuit breaker 2-poleQ2 Circuit breaker 2-poleQ3 Circuit breaker 2-poleQ4 Circuit breaker 2-poleS7 Switch (Generator-compressor)S8 Switch automatic control systemT13 Current transformer for N13X1 Socket outletX2 Socket outletX3 Socket outletY2 Solenoid valve (Generator action)


- 30 -


Generator function: Turn switch S7 to position 1. The solenoid valve Y2via the speed regulator controls the motor and allowsit to reach maximum speed (the normal controlsystem is switched off). Lamp H3 is activated. Timerelay K7 disconnects the sockets from the generatorduring 4 sec, after which the sockets X1, X2, X3 areunder tension. The generator can be switched off by turning switchS7 to position 0. If switch S7 is turned on, lamp H4 and ecologiser E1are activated. E1 senses continuously the current tothe sockets. If no current is sensed, time relay K8 isactivated. This time relay deactivates the solenoidvalve Y2 so that the speed regulator is againcontrolled by the normal compressor control system.When in this condition E1 senses current to thesockets, the solenoid valve Y2 is re-activatedimmediately by K8. Time relay K7 disconnects thesockets from the generator during 4 sec, after whichthe sockets X1, X2, X3 are under tension.

- 31 -

GENERATOR DDG IT 230/400V WITHOUT AUTOMATIC CONTROL SYSTEM


H3

S6u

EA

A1

A2

K535

52 51

S7

P

B

R Y2

K512

34

56

78

X1.3

L2 N

NL2

16A

c54c6c0

U V W

V1

U1

W1

NN

X1.1X1.2

L1 L2 L3 L2N N

NL3

L2 L116A NL2

16A

10A

Q1

16A 10A 16A

G

NW1V1U1G3

c54c6c0c54c6c0c0c0

C6C0C0

b3

C0

1313

N

12

3

13

b6 b6

12

b6

b3

b0

b034

W1

12

b54

b0

b6

12

b54 b54

b316b0 b3 b3

N

b616

W1

b0

b016

b6

W1

13

b6

12

b3

L A2

A1

PETR

14 12 11

R<

K6 D1


Reference NameD1 DiodeG3 GeneratorH3 Lamp (Power Control)

K5 Contactor/4-pole

K6 Insulation monitoring relay

Q1 Main circuit breaker 4-pole + shunt tripcoil

S6 Thermalcontact

S7 Switch (Generator-compressor)X1.1 Socket outletX1.2 Socket outletX1.3 Socket outletY2 Solenoid valve (Generator action)


- 32 -


Generator function: Turn switch S7 to position 1. The solenoid valve Y2via the speed regulator controls the motor and allowsit to reach maximum speed (the normal controlsystem is switched off). Lamp H3 is activated andsockets X1.1, X1.2, X1.3 are under tension. The generator can be switched off by turning switchS7 to position 0. In the case of an insulation fault, the yellow LED onthe insulation monitoring relay K6 of the system isactivated. When the yellow LED of K6 is active, areset can only occur by halting and restarting theassembly.

- 33 -

GENERATOR DDG IT 230/400V WITH AUTOMATIC CONTROL SYSTEM


H3

S6u

EA

A1

A2

K535

52 51

S7

P

B

R Y2

K512

34

56

78

X1.3

L2 N

NL2

16A

c54c6c0

U V W

V1

U1

W1

NN

X1.1 X1.2L1 L2 L3 L2N N

L1 L2 L3 N

NL3

L2 L116A NL2

16A

10A

Q1

16A 10A 16A

G

NW1V1U1G3

c54c6c0c54c6c0c0c0

C6C0C0

b3

C0

c6c0c0c0

13

N

12

3

b6 b6

12

b6

b3

b0

b034

W1

12b54

b0

b6

12

b54 b54

b316b0

N

b616

W1

b0

b016

b6

W1

13

b6

12

b3

13b3

34S8

H4

A1

A2

K8

13b3

A1

A2

K7

b6

12

b6

12

b6

9

b3 b3

b3

b3b3b3 b6

b6b3

b3

11

15

L A2

A1

PETR

14 12 11

R<

K6D1

2 134567

E1

To Circuitdiagram

9822 0797 01

Reference NameD1 DiodeE1 EcologiserG3 GeneratorH3 Lamp (Power Control)

H4 Lamp automatic control systemK5 Contactor/4-pole


K7 Time relaisK8 Time relaisQ1 Main circuit breaker 4-pole + shunt

tripcoilS6 Thermalcontact

S7 Switch (Generator-compressor)S8 Switch automatic control systemX1.1 Socket outletX1.2 Socket outletX1.3 Socket outletY2 Solenoid valve (Generator action)


- 34 -


Generator function: Turn switch S7 to position 1. The solenoid valve Y2via the speed regulator controls the motor and allowsit to reach maximum speed (the normal controlsystem is switched off). Lamp H3 is activated. Timerelay K7 disconnects the sockets from the generatorduring 4 sec, after which the sockets X1.1, X1.2, X1.3are under tension. The generator can be switched off by turning switchS7 to position 0. If switch S7 is turned on, lamp H4 and ecologiser E1are activated. E1 senses continuously the current tothe sockets. If no current is sensed, time relay K8 isactivated. This time relay deactivates the solenoidvalve Y2 so that the speed regulator is againcontrolled by the normal compressor control system.When in this condition E1 senses current to thesockets, the solenoid valve Y2 is re-activatedimmediately by K8. Time relay K7 disconnects thesockets from the generator during 4 sec, after whichthe sockets X1, X2, X3 are under tension.

- 35 -

GENERATOR DDG IT 230V, 6 kVA


X1.3

L1 L2

L2L1

16A

c54c0c0

X1.1X1.2

L3L2

L1

32A

L2L1

16A

H3

S6u

EA

A1

A2

K5

52 51

S7

P

B

R Y2

K512

34

56

U1

V1

W1

1V1

1U1

1W1

W1

L1 L2 L3 1L1

1L2

16A

Q1

16A 16A

b3

G

G3

U2 V2W2

U1 V1 W1

1313

W1

V1

1612

3

13

b6 b6

12

b6

b3

b0

b6

b6

b3

V1 13

12 12

b3

16

b016

b0V1

35

34

c54c0c0e54c0c0c0

c0c0c0

c0c0c0

b0

L1

L2

b54

b0

b6

12

b54 b54

b3b0b0

L A2

A1

PETR

14 12 11

R<

K6 D1

c0

c0


Reference NameD1 DiodeG3 GeneratorH3 Lamp (Power Control)

K5 Contactor/4-pole


Q1 Main circuit breaker 4-pole + shunt tripcoil

S6 Thermalcontact

S7 Switch (Generator-compressor)X1.1 Socket outletX1.2 Socket outletX1.3 Socket outletY2 Solenoid valve (Generator action)


- 36 -


Generator function: Turn switch S7 to position 1. The solenoid valve Y2via the speed regulator controls the motor and allowsit to reach maximum speed (the normal controlsystem is switched off). Lamp H3 is activated andsockets X1.1, X1.2, X1.3 are under tension. The generator can be switched off by turning switchS7 to position 0. In the case of an insulation fault, the yellow LED onthe insulation monitoring relay K6 of the system isactivated. When the yellow LED of K6 is active, areset can only occur by halting and restarting theassembly.

- 37 -

CIRCUIT DIAGRAM REFINARY EQUIPMENT 9822 0909 00 (ALL TYPES)

G1G2B+

D+WD-

M1M

K1H1 H2 86

85

K2K3

S2

K9

3A

S3

Y1P1K0

Y20S32

K9

N1

V1

K4

K4

V2

K1 K2

86

87a

87a

3 9 9 119

30 87

30

87

K3

S5

K0

87a

87a

u

30

30

30

86

87

87a

87

30 87

30

85

86

85

86

85

86

85

86 2 8 3

856

7

86

85

87

21

20

22 23

30

15

87a8710

30

30

14

13

30 S4

12V DC

12 12 12 12 12

h

12 12 12 12 12 12 12

S1

F1

0123

234

510A 21

34

u

p

143 8

652 7

- 38 -

Reference NameF1 Circuit Breaker (10 A)G1 AlternatorG2 BatteryH1 Temperature Alarm LampH2 General Alarm LampK0 Starter Solenoid (part of M1)K1 Shut-down RelayK2 Blocking RelayK3 Override Start RelayK4 Start RelayK9 Auxilary Relay Safety CircuitM1 Starter MotorN1 Overspeed ModuleP1 HourmeterS1 Contact Switch (Off-On-

Override-start)S2 Temperature Switch EngineS3 Oil Pressure Switch EngineS4 Temperature Lamptest SwitchS5 Temperature Switch CompressorS32 Test Button OverspeedY1 Fuel Solenoid ValveY20 Solenoid for Overspeed

Protection ValveV1 DiodeV2 Diode

- 39 -

MARKINGS AND INFORMATION LABELS

Compressor outlet temperature too high.

Compressor outlet temperature.

Compressor outlet pressure.

Danger, outlet gases.

Danger, hot surface.

Electrocution hazard.

Atlas Copco mineral compressor oil.

Atlas Copco synthetic compressor oil.

Atlas Copco mineral engine oil.

Atlas Copco synthetic engine oil.

Manual.

Read the instruction manual before working on the battery.

Reset fuse.

On / off button.

Manual override switch.

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 device.

Use diesel fuel only.

2.7 bar(39 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)).

Horizontal towbar position required in case of coupling.

Earthing connections.

Generator

Insulation fault.

0 = OFF1 = ON

- 40 -

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

(A) Parking position of jockey wheel (adjustable towbar)(B) Rear-end of compressor upwind

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. Locate therear-end of the compressor upwind, away fromcontaminated wind-streams and walls. Avoidrecirculation of exhaust air from the engine. Thiscauses overheating and engine power decrease.

The operator is expected to apply allrelevant Safety precautions (generator).

Before putting the compressor in to use,check the brake system as described insection Brake shoe adjustment.After the first 100 km travel:Check and retighten the wheel nuts andtowbar bolts to the specified torque. Seesection Compressor / enginespecifications.Check the brake adjustment. See sectionBrake shoe adjustment.

(1)

(2)

(3)

(4)

(2)(2) (A)

(B)

- 41 -

TOWING INSTRUCTIONS

Label on towbar, towing instructions Non-adjustable towbar with standard support leg withoutbrakes

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 (3) completely downwardsand connect breakaway cable (4) to the vehicle.Secure jockey wheel (2) or support leg (1) in thehighest possible position. The jockey wheel isprevented from turning.

Adjustable towbar with jockey wheel and brakes

Towing position of jockey wheel

Before towing the compressor, ensurethat the towing equipment of the vehiclematches the towing eye or ballconnector, and ensure that the hood isclosed and locked properly.

(1)(4)(2)

(3)

(4)

(2)(2)

- 42 -

HEIGHT ADJUSTMENT(with adjustable towbar)

• Remove spring pin (1).• Release locking nut (2).• Adjust required height of the towbar.• Tighten locking nut (2) by hand.• Secondly tighten locking nut (2) with a tightening

torque corresponding to table. With an extension tube (3) (”A” corresponding to table) and handforce (”B” corresponding to table) 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.

SPILLAGE-FREE INSTRUCTION

This compressor is fitted with a leak-proofundercarriage in order to protect the environment.Any leaking fluid is collected in case of malfunctions.This fluid can be removed via outlets, normallysecured by caps.Tighten the caps firmly and check for leakages.Please observe the locally applicable environmentalregulations when removing the leaking liquid.

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 (XXX) M [Nm/lbf.ft.] ”A” [mm/in] ”B” [N/lbf]ZV 2000 250 - 300 / 185 - 220 600 / 23.4 420 - 500 / 95 - 110ZV 2500 350 - 400 / 260 - 295 600 / 23.4 580 - 660 / 130 - 145

Attention:

- 43 -

INSTRUCTIONS BALL COUPLING (OPTION)

The coupling (ball coupling) on the tow bar is typeapproved. The maximum load at the coupling may notbe exceeded. When coupling lower the jockey wheel to the ground.Reverse the car up to the compressor or, in the case ofa small compressor, manoeuvre the compressor up tothe car's trailer coupling.

Coupling:Open coupling jaw by pulling the lever vigorouslyupwards in the direction of the arrow. Lower theopened coupling onto the ball of the vehicle couplingand the lever will automatically be lowered. Closingand locking are carried out automatically. Check the"+" (see figure) position!Connect the breakaway cable and electrical plug(option) to the towing vehicle. Raise the jockey wheelup fully and secure by firmly clamping it. Releaseparking brake before setting off.Visual check: the ball should no longer be visiblein coupled condition.

Uncoupling:Lower the jockey wheel. Disconnect breakaway cableand electrical plug. Pull the lever vigorously upwardsin the direction of the arrow and hold. Wind downjockey wheel (option) and lift the compressor off theball of the towing vehicle.Secure the compressor by means of a wheel chockand/or by applying the parking brake.

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 after opening the smalldoor (1).

The handle of the ball coupling and thehandbrake lever may never be used as amanoeuvring aid; internal componentsmay get damaged!

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

(1)

- 44 -

DIESEL PARTICLE FILTER (OPTION)

In order to be able to comply with local regulationsregarding exhaust gas, the machine can be equippedwith a diesel particle filter with control unit anddisplay.

This display (1) is especially designed for off-roadmachinery operated under severe conditions and isintegrated into the unit's control panel.The display has three LED bars, the upper bar (2) fortemperature indication, the middle bar (3) forpressure indication and the bottom bar (4) for alarms. A triangle shaped general alarm LED (6) and anacknowledge sensor (5) complete the display.The pressure and temperature indicating LEDs arecontrolled by parameters stored in a data logger unit.

After starting, the LEDs of the temperature andpressure bar will change from red via yellow to green,starting from the left. Yellow and finally redindicators on the right side of the bars will indicaterising values. Clogging of the filter will be indicatedfirst by LED's and secondly by a buzzer.The particle filter is self-cleaning up to a certaindegree. When backpressure rises, increasing engineload will result in a temperature rise so the soot willburn and subsequently backpressure will be lowered.Using low SAP oil (less sulphur) will create longerintervals between cleanings.In the bottom bar (4), alarms will be displayed whilean additional LED will submit additional informationin respect to temperature or backpressure. In case of an alarm, a triangle shaped LED (6) willstart flashing. By just touching the sensor (5) the errorwill be acknowledged and the LED will be off. In case an alarm is only acknowledged, without anyactions taken to eliminate the problem, the alarm willbe repeated two more times at intervals of 10 minutes.After the third acknowledgement the triangle shapedLED will be off while the corresponding alarm LEDis continuously lighted.A sounding buzzer in combination with the yellowLED lit at the right of the pressure bar (3) means thatthe machine has to be switched to full until the alarmis off.For Error Codes refer to the paragraph Problemsolving.

ANTI-FROST DEVICE (OPTION)

The anti-frost device consist of a manualy operatedby-pass valve (1) on the oil cooler to prevent freezingof the pneumatic tools at low ambient temperatures(partial by-pass).As soon as the ambient temperature drops below20° C (68° F) it is recommended to open the valve andby-pass the oil cooler. The outlet air temperature willincrease with 13 - 16° C (23 - 29° F) and condensationin the air will be reduced.It is also recommend to use the by-pass valve in casethe compressor is used at partial load for a long time.

When a diesel particle filter is installed,only use diesel with less than 50 ppmsulphur.

(5)(6) (4)

(2)(1) (3)

It is recommended to operate themachine at full load for at least 25% of adaily shift, in order to prevent cloggingof the particle filter.

(1)

- 45 -

STARTING / STOPPING

BEFORE STARTING

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

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 type and viscosity grade of the engine oil.

3. Check the level of the compressor oil. The pointer of oil level gauge (OLG) should register in the green range. Add oil if necessary. See section Oil level check 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. In case of start up of the unit, after running out of fuel, pump up the fuel manually with the fuel hand pump before starting.

6. Drain any water and sediment from the fuel filters until clean fuel flows from the drain cock.

7. Drain leaking fluid from the frame.8. Press vacuator valves (VV) of the air filter to

remove dust.9. 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.

10. 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.

- 46 -

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

To preheat if necessary push the cold start button S6for a short period.

STARTING PROCEDURE (WITH COLD START; OPTION)

Reference NameP1 HourmeterF1 Circuit breaker buttonPG 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)(F1)

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

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

A

B

(F1)

- 47 -

Starting procedure

1. Open air outlet valve.2. Press circuit breaker F1. For cold start press

button S6.3. Turn start switch S1 clockwise to position 1, lamp

H2 (general alarm lamp) will go on.4. Check correct operation of alarm lamps H1 and

H2 by pushing lamp test button S4. Both alarm lamps (red) should go on.

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

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

1 2 3 4 5 6

- 48 -

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

STARTING PROCEDURE (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)

(S4)

(F1)

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

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

A

B

(F1)

- 49 -

Starting procedure

1. Open air outlet valve.2. Press circuit breaker F1.3. Turn start switch S1 clockwise to position 1, lamp

H2 (general alarm lamp) will go on.4. Check correct operation of alarm lamps H1 and

H2 by pushing lamp test button S4. Both alarm lamps (red) should go on.

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

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

1 2 3 4 5 6

- 50 -

DURING OPERATION

Regularly carry out following checks:1. That the regulating valve (RV) is correctly

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

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

3. On compressors with aftercooler, check that the automatic drain of the water separator is operative without air leakage.

STOPPING PROCEDURE

1. Close the air outlet valves (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.

FAULT SITUATIONS AND PROTECTIVE DEVICES

• A fault which occurs with the engine, either: oil pressure (too low), oil temperature (too high) or alternator voltage (too low) will always and immediately cause the engine to cut out and the control lamp H2 will light up. By doing some simple checks, it can be determined what it was that caused the engine to fail: low oil level, clogged-up cooler, slack alternator belt tension or broken belt.

• When the outlet temperature of the element becomes too high, a thermocontact will also switch off the group immediately. Both control lamps H1 and H2 will light up. Both control lamps will remain on until the group has been restarted (start switch to position 3) or the contact is turned off (start switch to position 0); also when, due to cooling off, the thermocontact has closed again (= memory function).

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

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

3 min

1 2 3 4

A

B

(F1)

- 51 -

FUNCTIONAL DESCRIPTION OF GENERATOR (OPTION)

Control panel (generator) Earth pin

Start the unit in accordance with the normalprocedure (see section Starting / Stopping). Let themotor warm up until it reaches operationaltemperature. Turn the green switch S7 to position 1.The normal control system is switched off and themotor speed increases to reach the maximum.The green lamp H3 in the switch S7 is activated,showing that sockets X1, X2 and X3 are undertension.The generator can be switched off by turning thegreen switch S7 to position 0.

Generator control box

Protective deviceThe generator is protected by circuit breakers thatswitch off if a connected electrical device has anelectrical fault.

H3 Lamp (green, power ON)S7 Switch (generator - compressor)X1 Socket 110 V/ 32 AX2 Socket 110 V/ 16 AX3 Socket 110 V/ 16 AGND Terminal earth cable

Before switching on the generator,always place the earth pin in position.Check the cable connection betweenearth pin and the GND-terminal on theunit.

DDG 110V WITHOUT AUTOMATIC CONTROL SYSTEM

(X3) (H3/S7) (GND)(X2)(X1)

Avoid high inductive loads (e.g.welding). High inductive loads candamage the generator.

min

400

Q1 Main circuit breaker 2-poleQ2 Circuit breaker 2-poleQ3 Circuit breaker 2-poleQ4 Circuit breaker 2-pole

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

- 52 -

Control panel (generator) Earth pin

As soon as the generator is switched on, the automaticcontrol system will continuously check for electricload in order to rev up the engine from idle to nominalspeed only when needed. This saves fuel and reducesemissions.What is more, with the current continuouslymonitored, a consumer having just been switched onis temporary disconnected from the generator to bere-connected as soon as the engine reaches nominalspeed. This is a safety mechanism to protect generatorand engine below nominal speed.

Operation with automatic control switch S8“OFF”• Switch generator main switch S7 “ON”.• Generator is disconnected from socket.• Engine reaches nominal speed.• Generator is re-connected after 4 secs.• Power is now available until the generator main

switch S7 is turned “OFF”.

Operation with automatic control switch S8“ON”• Switch generator main switch S7 “ON”.• Generator is disconnected from socket.• Engine reaches nominal speed.• Generator is re-connected after 4 secs.• If a consumer is connected, the engine goes on for

60 secs. before falling back to idle speed.• Generator is in standby. As soon as any consumer

is switched on, the routine is repeated from step 2.

H3 Lamp (green, power ON)S7 Switch (generator - compressor)H4 Lamp automatic control systemS8 Switch automatic control systemX1 Socket 110 V/ 32 AX2 Socket 110 V/ 16 AX3 Socket 110 V/ 16 AGND Terminal earth cable

Before switching on the generator,always place the earth pin in position.Check the cable connection betweenearth pin and the GND-terminal on theunit.

DDG 110V WITH AUTOMATIC CONTROL SYSTEM (OPTION)

(X3) (H3/S7)(H4/S8) (GND)(X2)(X1)


min

400

- 53 -


Protective deviceThe generator is protected by circuit breakers thatswitch off if a connected electrical device has anelectrical fault.

Control panel (generator) Generator control box

Q1 Main circuit breaker 2-poleQ2 Circuit breaker 2-poleQ3 Circuit breaker 2-poleQ4 Circuit breaker 2-pole


Generator DDG 230/400V:S7 SwitchH3 Lamp (green)X1.1 Socket 400 V/ 16 AX1.2 Socket 230 V/ 16 AX1.3 Socket 230 V/ 16 AGND Terminal earth cable

Generator DDG 230V:S7 SwitchH3 Lamp (green)X1.1 Socket 230 V/ 16 AX1.2 Socket 230 V/ 16 AX1.3 Socket 230 V/ 16 AGND Terminal earth cable

DDG 230/400V AND 230V - 3PH WITHOUT AUTOMATIC CONTROL SYSTEM

(X1.3)(X1.2)(X1.1) (H3/S7) (GND)

Generator DDG 230/400V:Q1 Main circuit breaker 4-pole + shunt trip coilK6 Insulation monitoring relay

Generator DDG 230V:Q1 Main circuit breaker 3-pole + shunt trip coilK6 Insulation monitoring relay


- 54 -

Start the unit in accordance with the normalprocedure (see section Starting / Stopping). Let themotor warm up until it reaches operationaltemperature. Turn the green switch S7 to position 1. The normal control system is switched off and theengine speed increases to reach the maximum. The green lamp H3 in the switch S7 is activated,showing that sockets X1.1, X1.2 and X1.3 are undertension. The generator can be switched off by turning thegreen switch S7 to position 0.

Protective deviceThe generator is protected by circuit breakers thatswitch off if a connected electrical device has anelectrical fault.The insulation is monitored by relay K6.When the yellow LED on the insulation monitoringrelay K6 is activated, it means that a serious insulationfault has occured.The insulation monitoring relay K6 is adjusted to10 kΩ. This adjustment may not be changed.The generator temperature is monitored by a thermalcontact (S6).

Control panel (generator)

As soon as the generator is switched on, the automaticcontrol system will continuously check for electricload in order to rev up the engine from idle to nominalspeed only when needed. This saves fuel and reducesemissions.What is more, with the current continuouslymonitored, a consumer having just been switched onis temporary disconnected from the generator to bere-connected as soon as the engine reaches nominalspeed. This is a safety mechanism to protect generatorand engine below nominal speed.


Generator DDG 230/400V:H3 Lamp (green, power ON)S7 Switch (generator - compressor)H4 Lamp automatic control systemS8 Switch automatic control systemX1.1 Socket 400 V/ 16 AX1.2 Socket 230 V/ 16 AX1.3 Socket 230 V/ 16 AGND Terminal earth cable

DDG 230/400V AND 230V - 3PH WITH AUTOMATIC CONTROL SYSTEM (OPTION)

(X1.3)(X1.2)(X1.1) (H3/S7)(H4/S8) (GND)

Generator DDG 230V:H3 Lamp (green, power ON)S7 Switch (generator - compressor)H4 Lamp automatic control systemS8 Switch automatic control systemX1.1 Socket 230 V/ 16 AX1.2 Socket 230 V/ 16 AX1.3 Socket 230 V/ 16 AGND Terminal earth cable

- 55 -

Operation with automatic control switch S8“OFF”• Switch generator main switch S7 “ON”.• Generator is disconnected from socket.• Engine reaches nominal speed.• Generator is re-connected after 4 secs.• Power is now available until the generator main

switch S7 is turned “OFF”.

Operation with automatic control switch S8“ON”• Switch generator main switch S7 “ON”.• Generator is disconnected from socket.• Engine reaches nominal speed.• Generator is re-connected after 4 secs.• If a consumer is connected, the engine goes on for

60 secs. before falling back to idle speed.• Generator is in standby. As soon as any consumer

is switched on, the routine is repeated from step 2.


Protective deviceThe generator is protected by circuit breakers thatswitch off if a connected electrical device has anelectrical fault.The insulation is monitored by relay K6.When the yellow LED on the insulation monitoringrelay K6 is activated, it means that a serious insulationfault has occured.The insulation monitoring relay K6 is adjusted to10 kΩ. This adjustment may not be changed.The generator temperature is monitored by a thermalcontact (S6).

Generator DDG 230/400V:Q1 Main circuit breaker 4-pole + shunt trip coilK6 Insulation monitoring relay

Generator DDG 230V:Q1 Main circuit breaker 3-pole + shunt trip coilK6 Insulation monitoring relay



- 56 -

MaintenancePREVENTIVE MAINTENANCE SCHEDULE

The schedule contains a summary of the maintenanceinstructions. Read the respective section before takingmaintenance measures.When servicing, replace all disengaged packings, e.g.gaskets, O-rings, washers.For engine maintenance refer to Engine OperationManual.The maintenance schedule has to be seen as aguideline for units operating in a dusty environmenttypical to compressor applications. Maintenanceschedule can be adapted depending on applicationenvironment and quality of maintenance.

USE 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.

Unauthorised modifications can result ininjuries or machine damage.

Always keep the machine tidy to preventfire hazard.

Poor maintenance can void anywarranty claims.

MAINTENANCE SCHEDULE COMPRESSOR

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

after initial start-upYearly or every 500 hours

Service pak - 2912 4391 06For the most important subassemblies, Atlas Copco has developed service kits that combine all wear parts. These service kits offer you the benefits of genuine parts, save on administration costs and are offered at reduced price, compared to the loose components. Refer to the parts list for more information on the contents of the service kits.Check engine oil level xCheck compressor oil level x

Check fuel level xEmpty air filter vacuator valves xDrain water from fuel filter x(to be continued on page 58)

- 57 -

Maintenance schedule(continuation of page 57)

Daily Initially or 50 hours after initial start-up

Yearly or every 500 hours

Check air intake vacuum indicators xFor spillage free: drain fluids out of frame xCheck general conditions (leaks, damaged parts, loose bolts, trouble in previous operation)

x

Check during operation: meters and lamps, noise, colour exhaust fumes

x

Check electrolyte level and terminals of battery x xCheck tyre pressure x xCheck for leaks in air-, oil- or fuel system x xCheck oil coolers xCheck engine minimum and maximum speeds x xCheck torque of wheel nuts x xCheck brake system (if installed) and adjust if necessary x xTest safety valve xGrease door hinges xGrease coupling head and all its moving parts / shaft xCheck joints of height adjustment adjustable towbar xCheck rubber flexibles (2) xCheck shutdown switches xAdjust fan V-belt (3) xClean fuel tank xChange compressor oil xReplace compressor oil filter xReplace air filter element (1) x(to be continued on page 59)

- 58 -

Notes

Maintenance schedule(continuation of page 58)

Daily Initially or 50 hours after initial start-up

Yearly or every 500 hours

Replace safety cartridges (1) (option) xChange engine oil (3) (4) (5) xReplace engine oil filter (3) xReplace fuel filter (3) (6) (8) xAdjust engine inlet and outlet valves (3) x (7)Replace PD / QD filter (option) xReplace separator element After 1000 running hours or after max. 2 years

1. More frequently when operating in a dusty environment.2. Replace all rubber flexibles each 6 years, according to DIN 20066.3. Refer to the Deutz operation manual.4. 500 hours only valid when using PAROIL E.5. Also drain engine oil from engine oil cooler

(see chapter Main Parts, DPec = Drain plug engine oil cooler).6. In case of poor fuel quality, replace fuel filter more frequently.7. The valves need to be adjusted for the first time before 500 running hours.8. Option, additional fuel filter: heavy duty filter element 2914 8092 00, to be ordered separately.9. Consult Atlas Copco.

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.

- 59 -

DIESEL PARTICLE FILTER

every 500 hrs every 1500 hrsDiesel particle filter * clean replace

*Soot is toxic. It must be handledaccording local regulations for toxicwaste. Cleaning and replacing of thediesel particle filter may only be done byqualified and authorised personel.

- 60 -

MAINTENANCE SCHEDULE UNDERCARRIAGE

Initially IntervalWheelsTyre pressure Before each runCheck wheel bolts for firm seating Before first runCheck hub caps for firm seating 2,500km/annuallyCheck tyres for uneven wear 2,500km/annuallyCheck lateral play of bearings After 500 km 2,500km/annuallyCheck brake lining wear 5,000km/annually

TowbarCheck coupling head for wear, operation and fastening Before first run 5,000km/annuallyCheck brake play After first run 2,500km/annuallyCheck height adjustment facility Before each run, during first

500 km5,000km/annually

Check reversing lever for ease of motion 2,500 km 5,000km/annuallyCheck safety cable and bowden cable for damage 5,000km/annuallyCheck/ adjust brake system (if installed) Before first run 2,500km/annually

LubricationCoupling head and all its moving parts/shaft Before first run 2,500km/annuallyOverrun brake Before first run 5,000km/annuallyReversing lever Before first run 5,000km/annuallyOverrun coupling Before first run 5,000km/annuallyJoints of height adjustable towbar 5,000km/annuallyBearings (conventional bearings only) 5,000km/annually

- 61 -

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 E xtra is a Synthetic ultra high performancediesel engine oil with a high viscosity- index. AtlasCopco PAROIL E xtra is designed to provideexcellent lubrication from start-up in temperatures aslow as -20°C (-4°F).PAROIL E is a mineral based high performancediesel engine oil with a high viscosity- index. AtlasCopco PAROIL E is designed to provide a high levelof performance and protection in ‘standard’ ambientconditions as from -5°C (23°F).

Type of lubricant Compressor** Engine*between 30°C (86°F) and 40°C (104°F) PAROIL S PAROIL Ebetween 30°C (86°F) and -5°C (23°F) PAROIL M

PAROIL SPAROIL E

between -5°C (23°F) and -20°C (-4°F) PAROIL S PAROIL E xtra

*If you want to use another brand of oil,consult the engine instruction manual.

**It is strongly recommended to use AtlasCopco branded lubrication oils for thecompressor. If you want to use anotherbrands of oil, consult Atlas Copco.

- 62 -

OIL SPECIFICATIONS

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

COMPRESSOR OIL

Mineral compressor oil PAROIL M

Synthetic compressor oil PAROIL S

Mineral engine oil PAROIL E

Synthetic engine oil PAROIL E xtra

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 1604 6060 01can 20 5.3 1604 6059 01

- 63 -

OIL LEVEL CHECK

CHECK ENGINE OIL LEVEL

Also consult the Engine Operation Manual for the oilspecifications, viscosity recommendations and oilchange intervals.For intervals, see Preventive maintenance schedule.Check engine oil level according to the instructions inthe Engine Operation Manual and if necessary top upwith oil.

CHECK COMPRESSOR OIL LEVEL

With the unit standing horizontal, check the level ofthe compressor 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 the oil filler plug (2),ensure that the pressure is released byopening an air outlet valve (3).

(3)

(1)

(2)

- 64 -

OIL AND OIL FILTER CHANGE

ENGINE OIL AND OIL FILTER CHANGE

See section Preventive maintenance schedule.

The quality and the temperature of the oil determinethe oil change interval.The prescribed interval is based on normal operatingconditions and an oil temperature of up to 100 °C(212 °F) (see section Preventive maintenanceschedule).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) (5) and stop the compressor. Wait until the pressure is released through the automatic blow-down valve. Unscrew the oil filler plug (2) one turn. This uncovers a vent hole, which permits any pressure in the system to escape.

2. Drain the compressor oil by removing all relevant drain plugs. Drain plugs are located at the air receiver (DPar) and compressor element (DPcv, DPosv). Catch the oil in a drain pan. Screw out the filler plug to speed up draining. After draining, place and tighten the drain plugs.

3. Remove the oil filters (3), 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 (4) is in the upper part of the green area. Be sure that no dirt gets into the system. Reinstall and tighten the filler plug.

6. 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 (5). Screw out filler plug (2) and add oil until the pointer of the oil level gauge (4) 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

(5)

(4)

(2)(3) (1)

Never add more oil. Overfilling results inoil consumption.

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COMPRESSOR OIL FLUSHING PROCEDURE

To avoid problems when changing over to a new typeof oil (see table) a special Compressor Oil FlushingProcedure has to be followed. The table is only validin case the replaced oil has not exceeded its lifetime.For more information consult Atlas Copco Servicedept.Aged oil can be recognized best by using an oilsampling analysis program. Indicators for aged oil arestrong smell, or contamination like sludge andvarnish inside the oil vessel and oil stop valve or abrownish colour of the oil.Whenever aged oil is discovered, eg. when changingthe oil separator, contact Atlas Copco Service dept. tohave your compressor cleaned and flushed.1. First thoroughly drain the system when the oil is

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

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

element.

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

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

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

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

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

for 15 minutes and check for leakage. 10. Check the oil level and top up if necessary.11. Collect all waste lubricant used during the

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

Vessel cover contaminated clean

Vesselcontaminated clean

Not respecting compressor oil changingintervals according to the maintenanceschedule, can lead to serious problems,including fire hazard! The manufacturerdoes not accept any liability for damagearising from not following themaintenance schedule or not usinggenuine parts.

Instructions on replacing the oilseparator element are available fromAtlas Copco Service dept. * When changing over to the same oil within the oil changing interval, draining is sufficient

** Change over not recommended

PAROIL M PAROIL S PAROIL SxtremePAROIL M draining * flushing flushingPAROIL S draining ** draining * drainingPAROIL Sxtreme draining ** draining draining *

- 66 -

CLEANING COOLERS

Keep the oil-coolers (1) and (2) clean to maintain thecooling efficiency.The fan side surface of compressor- and engine oilcooler is accessible by removing the fan cowl upperpart.The opposite surface of compressor- and engine oilcooler is accessible by removing the centre part of thefront baffles.

Steam cleaning in combination with a cleansing agentmay be applied in order to remove also the dirtsticking to the cooler fins.

Close the service door(s).

CLEANING FUEL TANK

Place an appropriate drain pan under the drainplug(see chapter Main Parts, DPec) of the fuel tank.Remove the drain plug.Lift the towbar (see chapter Main Parts, TB) and tiltthe compressor approx. 15° to remove all fuel, dirtand water.Clean the fuel tank and fix the drain plug handtight.

Refill the fuel tank with clean fuel.

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

(1)

(2) To avoid damaging the coolers, anglebetween jet and coolers should beapprox. 90 °.

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

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

Observe all relevant environmental andsafety precautions.

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

- 67 -

CLEANING HARDHAT

Optimal cleaning of the HardHat can be obtained byapplying high pressure cleaning in combination withliquid soap.

BATTERY CARE

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

ELECTROLYTE

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

ACTIVATING A DRY-CHARGED BATTERY

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

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

reaches 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.

Before handling batteries, read therelevant safety precautions and actaccordingly.

Read the safety instructions carefully.

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

- 68 -

CHANGING TYRES

When changing a tyre, please observe that the arrowon the tyre in top position points in the drivingdirection (to the towbar).

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 (ASL).

SERVICE KITS

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

COMPRESSOR ELEMENT OVERHAUL

When a compressor element is due for overhaul, itneeds to be done by Atlas Copco. This guarantees theuse of genuine parts and correct tools with care andprecision.

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.

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

- 69 -

Adjustments and servicing proceduresADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM

(RV)

(AOV)

(SVsr)

(E)

(SR)

With generator

Without generator

- 70 -

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.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, pull out the

knob, 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) (see table); adjust if necessary with regulating valve (RV).

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 pushing the knob down.

7. Check the operation of the solenoid valve (SVsr) when equipped with a generator.

Xbar(e)

Ybar(e)

Z1 – Z2bar(e) bar(e)

XAHS 37 DD - XAHS 70 DD7 13.5 12 13.3 – 13.7XAS 47 DD - XAS 90 DD7 8.5 7 8.3 – 8.7XAS 57 DD - XAS 110 DD7 8.5 7 8.3 – 8.7

- 71 -

AIR FILTER ENGINE/COMPRESSOR

CLEANING THE DUST TRAP

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

RECOMMENDATIONS

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 9307 00A dirty safety cartridge (3) is an indication of amalfunctioning air filter element. Replace the elementand the safety cartridge in this case.The safety cartridge cannot be cleaned.

REPLACING THE AIR FILTER ELEMENT

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

2. Remove the element (4) from the housing (5).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 (7).

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)

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.

The filter element must be cleaned orreplaced when the yellow indicator (9)has reached the bottom of the vacuumindicator.

- 72 -

AIR RECEIVER

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

DRIVE BELT

SAFETY VALVE

Following checks must be carried out:• a check of the opening of the lifting gear, twice a

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

• a check of the set pressure once a year according to the local regulations. This check cannot be done on the 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.

Never retense or reuse the drive beltbetween engine and compressor.Consult Atlas Copco for replacement ofdrive belt.

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

(1)

- 73 -

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 2 mm(0.079 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 (see section Brake cableadjustment, 2).

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.

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 mm)2. Axle 5. Plug3. Brake cable

(1)(5) (3)

(2)

(4)

1. 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)

- 74 -

TEST PROCEDURE 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

- 75 -

WHEELS

WHEEL CHECK

• Check wheel bolts for firm seating (initially)• Check hub caps for firm seating (every 2,500 km

or anually)• Check tyres for uneven wear (every 2,500 km or

anually)• Check lateral play of wheel bearing. If necessary,

readjust.Compact bearings (every 2 years)Conventional bearings (after 500 km, every 2,500 km or anually)

LUBRICATION

Tapered type hub cap

Taper roller bearings and deep groove ballbearingAxles fitted with taper roller bearings arerecognizable by a tapered type hub cap, see Figure.Remove wheels and wheel hubs.Mark dismounted wheel hubs and bearing races sothat their identity is not mistaken during reassembly.Clean wheel hubs thoroughly inside and outside.Remove old grease totally.Clean taper roller bearings and seals (using diesel oil)and check for reuseability.Work BPW special longlife grease ECO_Li 91 intothe cavities between the taper roller and cage. Smeargrease into the hub's outer bearing race.

Greasing bearing race

Fill the hub caps to 3/4 full with grease.Fit wheel hubs, adjust the bearing play and fit the hubcaps.

- 76 -

Cylindrical hub cap shape

Compact bearingsCompact bearings are recognizable by cylindrical hubcap shape, see Figure.Compact bearings are maintenance-free due topermanent lubrication and are designed for highmileages.Therefore, there is no grease change or regreasingnecessary.

WHEEL BOLTS CHECK

Wheel bolts tightening

Tighten wheel bolts crosswise using a torque wrenchto the tightening torque in compliance with the table.

Tightening torques of wheel bolts

After the first run, likewise after eachwheel change.

Spannerwidth (mm)

Thread Tighteningtorque

17 (19) M 12x1.5 80 100 Nm

19 M 14x1.5 110 120 Nm

24 M 18x1.5 270 280 Nm

- 77 -

WHEEL BEARING ADJUSTMENT

Bearing play

Jack up the compressor, release brakes.Turn wheels manually and rock. If any bearing play is perceivable, adjust the bearings.

Conventional taper roller bearingsTaper roller bearings are recognisable by the conicalprofile of the hub cap.• Lever off hub cap. Remove split pin from axle nut

and tighten so that rotation of the wheel is slightly braked.

• Turn back the axle nut to the next possible split pin hole, by a maximum of 30 degrees.

• Insert split pin and bend ends slightly outwards.• Check wheel rotation, fit hub cap.

Important:The grease in the hub cap and bearing must not becontaminated with dirt during this job!

Compact bearingsCompact bearings are recognizable by theircylindrical hub cap shape.

If noticeable bearing play is felt, thecompact bearings should be replaced.

- 78 -

TOWBAR AND OVERRUN BRAKE

TOWBAR AND OVERRUN BRAKE CHECK

Check coupling head

Check coupling head for wear and correct operation.Check the wear indicator (use within the "+" rangeonly). Check the coupling head fastenings (see arrows,Figure) at regular intervals for firm seating.

Check the coupling head fastenings

Check height adjustment facility

After every adjustment the clamping nuts must bescrewed up tight and secured with the springelements.Tightening torque:M 24 = 250 - 350 NmM 32 = 350 - 400 NmCheck tight fit of the clamping nuts and correctpositioning of the adjustment facility.

Brake play check

Brake play check

The check is carried out visually on the stroke (x) ofthe overrun coupling.As soon as this is more than 50 mm when the brakesare applied, adjust the wheel brakes.Check towbar, handbrake lever, spring actuator,reversing lever, linkage and all movable parts for easeof movement.

Initially, then every 5,000 kilometres orannually.

Initially, before every journey, after 500kilometres, then every 5,000 kilometresor annually.

After the first run, then every 2,000 -3,000 kilometres.

(x)

- 79 -

Towbar

Check safety cable (1) for damage; every 5,000kilometres or annually.Check Bowden cable (2) on height-adjustableconnection devices for damage; every 5,000kilometres or annually.

LUBRICATION

Lubrication coupling head

Lubricate the coupling head

Oil ball coupling at regular intervals at the specifiedlocations and moving parts.Grease the contact surface of the ball of the towingvehicle.

Greasing towbar

Towbar bushes on the housing of theoverrun coupling

Apply general purpose grease via the grease nipplesuntil fresh grease can be seen emerging from thebushes.

Initially, then every 5,000 kilometres orannually.

(2)

(1)

At regular intervals. Initially, after 2,000 - 3,000 kilometres,every 5,000 kilometres.

- 80 -

Reversing lever

Reversing lever

Check reversing lever (1) for ease of motion.If fitted, apply general purpose grease via the greasenipple until fresh grease can be seen emerging fromthe bush.If grease nipples are not fitted, then apply oil to thereversing lever bush.

Lubrication points

Lubricate all moving parts and pivot pins atthe overrun coupling

All moving parts of drawbar, handbrake lever, springactuator, reversing lever, linkages etc. to be oiled orgreased as required.

Heigth adjusting device

Grease sliding locations on the height-adjusting device

Oil threaded parts and grease toothed parts.

Initially, after 2,000 - 3,000 kilometres,every 5,000 kilometres.

(1)

Initially, after 2,000 - 3,000 kilometres,every 5,000 kilometres.

For the first time after 2,000 - 3,000kilometres travelled, then every 5,000kilometres.

- 81 -

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.

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.

An electrical fault must be traced by anelectrician.

If it’s not possible to solve the problemwith this problem solving table, pleaseconsult Atlas Copco.

Problem Possible faults Corrective actions

1. Lamps (H1, H2) do not light up when switching (S1) to ”I” and applying lamp test.

a. Discharged or defective battery.

b. Loose battery cable(s) or oxidised terminals.c. Loose connection or damaged wiring.d. Contact switch (S1) defective.

e. Circuit breaker (F1) defective.

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

b. Check and correct if necessary.c. Check wiring and connections; correct if necessary.d. With (S1) switched in ”I”, check voltage between earth

and respectively each of the terminals of (S1).Voltage must register at each of the terminals; if not, replace (S1).

e. Replace circuit breaker.

2. General alarm lamp (H2) does not light up when switching (S1) to ”I”; lamp (H1) lights up when applying lamptest.

a. Lamp (H2) blown.b. Alternator (A)/regulator defective.

a. Replace lamp.b. Disconnect the wire from alternator terminal D+ and

connect it to terminal D–. If (H1) lights up, replace the alternator; if not, test (S1); see remedy 1d.

- 82 -

3. Temperature alarm lamp (H1) does not light up when switching (S1) to ”I” and applying lamp test.

a. Lamp (H1) blown.b. See fault 1d.

a. Replace lamp.b. See 1d.

4. Starter motor (S) does not crank engine (E) after switching startbutton (S1) to ” ”.

a. Low battery output. a. See remedy 1a.

5. Starter motor cranks engine when switching start switch (S1) to ” ”, but engine does not fire.

a. Contact switch (S1) defective.b. Fuel solenoid (Y1) defective.

c. Low battery output.

a. See remedy 1d.b. Check solenoid and its valve, correct or replace if

necessary.c. See 1a.

6. Engine fires, but general alarm lamp (H2) remains alight; engine stops when releasing start switch (S1).

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

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

7. Engine is running, but shuts down immediately after (S1) has been released.

a. Contact switch (S1) released too soon.

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

a. Release switch after engine oil pressure has built up above the minimum allowed value.

b. Stop at once, consult the Engine Operation Manual.c. Fill fuel tank.

8. General alarm lamp (H2) remains alight for over 5 seconds after starting.

a. Insufficient engine oil pressure or too high engine oil temperature.

b. Engine oil pressure switch (S3), or compressor temperature switch (S5) defective.

c. Relay (K1) defective.

a. Stop at once, consult Engine Operation Manual.

b. Stop at once, test switches, replace as necessary.

c. Replace (K1).

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

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

10. Compressor does not unload and engine keeps running at maximum speed when closing the air outlet valves; safety valve blows.

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

c. Unloading valve (UV) or its actuating piston stuck.

a. Check and repair.b. Adjust or repair regulating valve; see section

Adjustment of the continuous pneumatic regulating system.

c. Repair unloading valve assembly.


- 83 -

11. Compressor capacity or pressure below normal.

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

d. Engine does not run at max. speed.e. Oil separator element (OS) clogged.

a. Check equipment connected.b. Replace air filter element (AF).c. Speed regulation cable maladjusted; see section

Adjustment of the continuous pneumatic regulating system.

d. Check the maximum speed, service the fuel filter.e. Have element removed and inspected by an Atlas Copco

Service representative.

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

a. See faults 10.b. Safety valve (SV) opens too soon.

a. See remedies 10.b. Have safety valve adjusted; consult Atlas Copco.

13. Excessive compressor oil consumption. Oil mist being discharged from air outlet valve(s).

a. Restrictor in oil scavenging line (SL) clogged.b. Oil separator element (OS) defective.c. Oil level too high.

a. Dismount, clean and refit restrictor.b. Replace element.c. Check for overfilling. Release pressure and drain oil to

correct level.

14. Compressor shuts down through a shutdown switch.

a. Alternator V-belt broken or slipping.b. Compressor overheating.c. Engine oil pressure too low.d. Engine temperature too high.

a. Re-tense or replace V-belt.b. See condition 16.c. Check lubricating system.d. Check engine oil system; see Engine Operation Manual.

15. Air and oil mist expelled from air filter after stopping.

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

a. Repair valve.b. Consult Atlas Copco.

16. Compressor overheating. a. Insufficient compressor cooling.b. Oil cooler (OC) clogged externally.c. Oil system clogged internally.d. Oil level too low.

a. Relocate compressor.b. Clean cooler; see section Cleaning coolers.c. Consult Atlas Copco.d. See section Oil level check.

17. No air output. a. Drive belt broken. a. See section Problem solving.


- 84 -

Generator DDG 110V:

18. Circuit breakers are off (down). a. Short circuit or overload.b. Circuit breakers switched off.

a. Remedy fault. Switch on circuit breakers.b. Switch on circuit breakers.

19. Green lamp H3 is deactivated. a. Circuit breakers are off.b. Serious electrical fault.

a. Switch on circuit breakers.b. Consult Atlas Copco.

Generator DDG IT 230/400V:

20. Circuit breakers Q1 are off (down). a. Short circuit.b. Temperature in generator too high.

a. Remedy fault. Switch on circuit breakers.b. Check generator cooling.

21. Green lamp H3 is deactivated. a. Circuit breakers are off.b. Serious electrical fault.

a. Switch on circuit breakers.b. Consult Atlas Copco.


- 85 -

Diesel particle filter

No LED, triangle flashes. No Communikation between CB and PB. Consult Atlas Copco.

All Alarm LED flash, triangle shaped flashes.

Non compatible SW-Versions of CB and PB. Consult Atlas Copco.

Pressure 1 / Alarm 2 flash, triangle shaped flashes.

Lower Pressure Limit.

Pressure 1 / Alarm 4 flash triangle shaped flashes.

No change of pressure within 10 minutes. a. Start engine.b. Have pressure line cleaned.

Temp. 1 / Alarm 5 flash, triangle shaped flashes.

No change of temperature within 10 minutes. Check if engine is running and pressure sensor is correctly fitted.

Temp. 1 / Alarm 6 flash, triangle shaped flashes.

Damage of temperature probe.

Pressure 8 / Alarm 1 flash, triangle shaped flashes.

Upper Pressure Limit. Switch to full load.

Alarm 3 flashes, triangle shaped flashes. No RPM-Signal from the generator.

Alarm 7 flashes, triangle shaped flashes. Date and Time not correct, no recording of data. Consult Atlas Copco.

Alarm 1 flashes, triangle shaped flashes (Pressure 8 off).

Error Additive-Dosing. Consult Atlas Copco.

Alarm 8 flashes, triangle shaped flashes. Level Additive-Tank.

Alarm 4 flashes, triangle shaped flashes (Pressure 1 off).

Error PLC (Slave).

Alarm 5 flashes, triangle shaped flashes (Temp.1 off).

Error GSM (Slave).

Alarm 4-8 flash, triangle shaped flashes. Glass Cover dirty. Clean glass cover.

Filter does not regenerate spontaneously. Consult Atlas Copco.


- 86 -

Available options

1) Not in combination with HardHat2) Not on XAHS 37 DD - XAHS 70 DD7.

3) In order to obtain a spare key at the local ABUS dealer, the key code card mustbe presented. Please keep this card available.

4) Only for XAS 47 DD - XAS 90 DD7 with metal canopy.

Pressure vessel approval: CEASME

Undercarriage: Adjustable towbar with brakesAdjustable towbar without brakesFixed towbar with brakesFixed towbar without brakes (no road homologation)Simplified bumper 1)

Support (without undercarriage) 1)

Towing eyes: Loose ball couplingTowbar support: Jockey wheelRoad lights system: Reflectors only

Road lights system24 V adaptor

Air quality equipment: Aftercooler + water separatorAftercooler + water separator + PD filterAftercooler + water separator + PD/QD filtersAftercooler + water separator + reheater 1)

Aftercooler + water separator + PD filter + reheater 1)

Aftercooler + water separator + PD/QD filters + reheater 1)

Lubricator 2)

Anti-frost device 2)

Tool box: SingleSafety: Wheel chocks

Safety cartridgeSpark arrestor 1)

Exhaust particle filter 1)

Safety chain CE/ASMEAnti-theft 3)

Hose reel 1)

Inlet shutdown valve 1)

Spillage free frameFueltank with metal fillerneckAdditional fuel filterNon return valveAdditional literature set

Cold start: Cold start - 20 °CGenerator 4): 230/400 V - 6.5 kVA

230/400 V - 6.5 kVA Automatic230 V - 3 ph - 6.5 kVA110 V - 6 kVA110 V - 6 kVA Automatic

Canopy colour: singledouble 1)

- 87 -

Technical specificationsTORQUE VALUES

GENERAL TORQUE VALUES

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

For hexagon screws and nuts with strength grade 8.8

For hexagon screws and nuts with strength grade 12.9

CRITICAL TORQUE VALUES

Thread size Torque value (Nm / lbf.ft) M6 9 (6.5)M8 23 (17)M10 46 (35)M12 80 (59)M14 125 (92)M16 205 (151)

Thread size Torque value (Nm / lbf.ft) M6 15 (11)M8 39 (29)M10 78 (58)M12 135 (100)M14 210 (155)M16 345 (255)

Assemblies Torque value (Nm / lbf.ft)Wheel nuts 80 (59) +10/-0 %Bolts, axle/beams 80 (59) +/- 10 %Bolts, towbar/axle 80 (59) +/- 10 %Bolts, towbar/bottom 80 (59) +/- 10 %Bolts, towing eye/towbar 80 (59) +/- 10 %Bolts, lifting eye/flywheel housing 80 (59) +/- 10 %Bolts, engine/drive housing (M12) 80 (59) +/- 10 %Bolts, engine/drive housing (M14) 125 (92) +/- 10 %Bolts, compressor element/drive housing

80 (59) +/- 5 %

Safety switches 35 (26) +/- 5 %Joints adjustable towbar (M24) 275 (205) +/- 10 %Joints adjustable towbar (M32) 375 (280) +/- 10 %

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

- 88 -

SETTINGS OF SHUTDOWN SWITCHES AND SAFETY VALVES

Designation XAHS 37 DD - XAHS 70 DD7

XAS 47 DD -XAS 90 DD7


Engine oil pressure bar(e) 1.2 1.2 1.2psi 17.4 17.4 17.4

Engine oil temperature °C 127 - 133 127 - 133 127 - 133°F 260 - 270 260 - 270 260 - 270

Compressor temperature °C 116 - 120 116 - 120 116 - 120°F 241 - 248 241 - 248 241 - 248

Safety valve opening pressure- EC type bar(e) 14.5 10.5 10.5- ASME type psi 210 160 160

- 89 -

COMPRESSOR / ENGINE SPECIFICATIONS

REFERENCE CONDITIONS

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




Absolute inlet pressure bar(e) 1 1 1psi 14.5 14.5 14.5

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

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

psi 174 102 102

- 90 -

LIMITATIONS

1) For Hose Reel application: maximum ambient temperature 30°C (86°F).2) Cold start equipment not available at time of release.




Minimum effective receiver pressure bar(e) 4 3 3.6psi 58 43 52

Maximum effective receiver pressure, compressor unloaded

bar(e) 13.5 8.7 8.7psi 196 126 126

Maximum ambient temperature at sea level 1)

no aftercooler °C 45 45 45°F 113 113 113

with aftercooler °C 40 40 40°F 104 104 104

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

Minimum starting temperature, with coldstart equipment 2)

°C -20 -20 -20°F -4 -4 -4

Altitude capability see curves

- 91 -

ALTITUDE UNIT PERFORMANCE CURVES

Max. allowable working pressure as a function altitude and ambient temperature.

5000

4000

3000

2000

1000

0

14 32 50 68 86 104 122

-10 0 10 20 30 40 50

16.405

0

XAHS 37 DD - XAHS 70 DD7

13.124

9.843

6.562

3.281

8.0 bar(e)

9.0 bar(e)

10.0 bar(e)

11.0 bar(e)

12.0 bar(e)

116 psi

131 psi

145 psi

160 psi

174 psi

ALT

ITU

DE

m

ALT

ITU

DE

ft

TEMPERATURE °F

TEMPERATURE °C

5000

4000

3000

2000

1000

0

14 32 50 68 86 104 122

-10 0 10 20 30 40 50

16.405

0

XAS 47 DD - XAS 90 DD7

13.124

9.843

6.562

3.281

5.0 bar(e) 73 psi

6.0 bar(e) 87 psi

7.0 bar(e) 102 psi

ALT

ITU

DE

m

ALT

ITU

DE

ft

TEMPERATURE °F

TEMPERATURE °C

- 92 -

Max. allowable working pressure as a function altitude and ambient temperature.

5000

4000

3000

2000

1000

0

14 32 50 68 86 104 122

-10 0 10 20 30 40 50

16.405

0

XAS 47 DDG - XAS 90 DD7G

13.124

9.843

6.562

3.281

5.0 bar(e) 73 psi

4.0 bar(e) 58 psi

6.0 bar(e)87 psi

7.0 bar(e)102 psiA

LTIT

UD

E m

ALT

ITU

DE

ft

TEMPERATURE °F

TEMPERATURE °C

5000

4000

3000

2000

1000

0

14 32 50 68 86 104 122

-10 0 10 20 30 40 50

16.405

0


13.124

9.843

6.562

3.281

5.0 bar(e) 73 psi

4.0 bar(e) 58 psi

6.0 bar(e) 87 psi

7.0 bar(e) 102 psi

ALT

ITU

DE

m

ALT

ITU

DE

ft

TEMPERATURE °F

TEMPERATURE °C

- 93 -

PERFORMANCE DATA

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

1) Free Air Delivery (volume flow rate) is measured according to ISO 1217 ed.3 1996 annex D




DDG IT


Engine shaft speed, normal and maximum r/min 2400 2400 2750 2750Engine shaft speed, compressor unloaded r/min 1850 1850 1850 1850Engine shaft speed, generator at maximum load r/min - - 2700 -Free air delivery 1) no aftercooler l/s 32 43 31 50

cfm 68 91 66 106with aftercooler l/s 27 38 26 45

cfm 57 80 55 95Typical oil content of compressed air mg/m3 < 5 < 5 < 5 < 5

oz/1000 cu.ft < 0.005 < 0.005 < 0.005 < 0.005Engine oil consumption (maximum) g/h 12.3 12.3 15 15

oz/h 0.4 0.4 0.5 0.5Compressed air temperature at outlet valves

no aftercooler °C 90 88 93 93°F 194 190 199 199

with aftercooler °C 30 30 30 30°F 86 86 86 86

Noise level- Sound pressure level (LP), measured acc. to ISO 2151 under free field conditions at 7 m distance

dB(A) 70 70 70 72

- Sound power level (LW) complies with 2000/14/EC

dB(A) 98 98 98 98

Tolerance: The international standard ISO 1217 corresponds to following national standards:• +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (530 cfm) • British BSI 1571 part 1 • Swedish SS-ISO 1217• +/- 4% 250 l/s (530 cfm) < FAD • German DIN 1945 Part 1 • American ANSI PTC9

- 94 -

DESIGN DATA

Compressor

Engine

1) With filter change.

Number of compression stages 1




DDG IT


Make DeutzType D2011L02Coolant OilNumber of cylinders 2 2 2 2Bore mm 94 94 94 94

in 3.7 3.7 3.7 3.7Stroke mm 112 112 112 112

in 4.4 4.4 4.4 4.4Swept volume l 1554 1554 1554 1554

cu.in 94.8 94.8 94.8 94.8Output acc. to ISO 9249 G at normal shaft speed kW 21.6 21.6 23.3 23.3

hp 29 29 31.2 31.2- Load factor % 50 50 50 50Capacity of oil sump:- Initial fill l 8 8 8 8

US gal 1.76 1.76 1.76 1.76- Refill (max.) 1) l 6.5 6.5 6.5 6.5

US gal 1.43 1.43 1.43 1.43Capacity of cooling system l - - - -

US gal - - - -

- 95 -

Unit

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




DDG IT


Capacity of compressor oil system l 8 8 8 8US gal 2.1 2.1 2.1 2.1

Net capacity of air receiver l 16.7 16.7 16.7 16.7US gal 4.4 4.4 4.4 4.4

Capacity of fuel tank l 40 40 40 40US gal 8.8 8.8 8.8 8.8

Air volume at inlet grating (approx.) 1) m3/s 0.74 0.74 0.81 0.81cuft/s 26 26 29 29

- 96 -

DESIGN DATA FOR GENERATOR

Alternator

Electrical power circuit

Designation DDG 110V DDG IT 230V - 3 ph - 6 kVA

DDG IT 230/400V - 3 ph - 6 kVA

(XAS 47 DDG - XAS 90 DD7G/DDG IT)

Standard IEC 34-1 IEC 34-1 IEC 34-1Make MECC ALTE MECC ALTE MECC ALTEModel MR-1 -180/2 TR-1 -160/2 TR-2 -200/2Rated output kVA 6 6 6Degree of protection IP 23 23 23Insulation - stator class H H H

- rotor class H H HNumber of phases 1 3 3Number of leads 4 6 6


DDG IT 230/400V - 3 ph - 6 kVA


Rated continuous active power COP kW 5.5 4.8 4.8Rated power factor (lagging) 1 0.8 0.8Rated continuous apparent power 1 ph COP kVA 5.5 4 4Rated voltage 1ph line to line V 110 230 230Rated current 1ph A 50 16 16Frequency droop % <5 <5 <5Rated continuous apparent power 3 ph COP kVA - 6 6Rated voltage 3ph line to line V - 230 400Rated current 3ph A - 15 8.7

- 97 -

Circuit breaker

Fault current protection


DDG IT 230/400V - 3 ph - 6 kVA


Number of poles 2 3 4Rated current In 1ph A 50

In 1ph/3ph A 16/16 16/10Thermal release It 1ph A 50

It 1ph/3ph A 16/16 16/10Magnetic release Im A 3..5 In 3..5 In 3..5 In


DDG IT 230/400V - 3 ph - 6 kVA


Insulation resistance kOhm 10-80 10-80Residual current release Idn A 0.03

- 98 -

Unit dimensions

without brakes towbarfixed adjustable

Length mm 2980 3257 - 3495in 117.3 128.2 - 137.6

Width mm 1330 1330in 52.5 52.5

Height mm 1252 1252in 49.5 49.5

Weight (ready-to-operate) kg 720 725lb 1587 1598

with brakes towbarfixed adjustable

Length mm 3093 3460 - 3628in 121.8 136.2 - 142.8

Width mm 1330 1330in 52.5 52.5

Height mm 1252 1252in 49.5 49.5

Weight (ready-to-operate) kg 755 770lb 1655 1690

- 99 -

Dataplate1 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

Atlas Copco Airpower n.v.

Atlas Copco Airpower n.v.Boomsesteenweg 957

B-2610, WILRIJK0038

kg

kgkg1 -

A

CB

2 -kgD

S/N Manuf. year

(1) (2) (3)

(4)

(5)

(6)

(7)

(8)(9)

(10)(11)

(12)

(14)(13)

- 100 -

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.

- 101 -

Maintenance Log

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

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

Service hours Maintenance action Date By initials

- 102 -

EXAMPLE

Atlas Copco Airpower n.v. puorG ocpoC saltA eht nihtiw ynapmoc A

Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651 P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231 B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp

evitatneserper ocpoC saltA lacol ruoy tcatnoc esaelp ,ofni roF muigleB muigleBwww.atlascopco.com

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-01

-01

1 EC DECLARATION OF CONFORMITY

2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product 3 Machine name : Compressor (≥≥ 350 kW) 4 Machine type : 5 Serial number :

Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and Safety Requirements of this directive.

The machinery complies also with the requirements of the following directives and their amendments as indicated.

Directive on the approximation of laws of the

Member States relating to Harmonized and/or Technical

Standards used Att'mnt

a. x CE/32/79 tnempiuqe erusserP

b. CE/24/6002 ytefas yrenihcaM

EN ISO 12100-1 EN ISO 12100-2

EN 1012-1 EN 294 EN 349 EN 418 EN 563 EN 842 EN 953

EN 1037 EN 1050 EN 13478

d. Electromagnetic compatibility 2004/108/EC EN 61000-6-2 EN 61000-6-4

e. Low voltage equipment 2006/95/EC EN 60034

EN 60204-1 EN 60439

6

7

Atlas Copco Airpower n.v. is authorized to compile the technical file 8 The harmonized and the technical standards used are identified in the attachments hereafter

9

10 Conformity of the specification to the

Directives

Conformity of the product to the specification and by implication to the

directives11

12

13

gnirutcafunaM gnireenigne tcudorP yb deussI

14 Name15 Signature

16 Date

I

Following documents are provided with this unit:- Test Certificate- EC Declaration of Conformity:

- 103 -

Notes

- 104 -

Notes

- 105 -

Notes

- 106 -

Documents

2954 2140 03_XA(H)S37-57 DD_EN