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Instruction Manualfor Portable CompressorsEnglish
XRXO 667 Cd - XRXO 1400 CD7 Engine CAT C18 TTXRVO 727 Cd - XRVO 1550 CD7
ATLAS COPCO - PORTABLE AIR DIVISIONwww.atlascopco.com
Printed matter N°2954 4720 00
04/2010
Instruction Manualfor Portable Compressors
XRXO 667 Cd - XRXO 1400 CD7XRVO 727 Cd - XRVO 1550 CD7
Original instructions
Warranty and Liability LimitationUse only authorized parts.Any damage or malfunction caused by the use ctLiability.The manufacturer does not accept any liabilit orconversions made without the manufacturer's apNeglecting maintenance or making changes to t gfire risk.While every effort has been made to ensure that otassume responsibility for possible errors.
Copyright 2010, Atlas Copco Airpower n.v., AnAny unauthorized use or copying of the contentsThis applies in particular to trademarks, model d
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of unauthorized parts is not covered by Warranty or Produ
y for any damage arising from modifications, additions proval in writing.he setup of the machine can result in major hazards, includin
the information in this manual is correct, Atlas Copco does n
twerp, Belgium. or any part thereof is prohibited.enominations, part numbers and drawings.
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4.4.5 Power ON / OFF.................................... 304.4.6 Starting................................................... 304.4.7 Warming up ........................................... 314.4.8 Loading .................................................. 314.4.9 Stopping................................................. 324.4.10 Emergency stop ..................................... 334.4.11 Info......................................................... 334.4.12 Options................................................... 344.4.13 Service task confirmed .......................... 354.4.14 Service in advance ................................. 354.4.15 Pressure adjustment ............................... 35
5 Maintenance ............................................. 365.1 Liability...................................................... 365.2 Service paks ............................................... 365.3 Service kits................................................. 365.3.1 Storage ................................................... 365.3.2 Safety precautions.................................. 365.4 Preventive maintenance schedule .............. 375.5 Maintenance schedule compressor............. 375.6 Oil specifications........................................ 405.6.1 Compressor oil....................................... 405.6.2 Engine oil............................................... 415.7 Oil level check ........................................... 425.7.1 Check engine oil level ........................... 425.7.2 Check compressor oil level.................... 425.8 Oil and oil filter change ............................. 435.8.1 Engine oil and oil filter change.............. 435.8.2 Topping up the compressor oil .............. 435.8.3 Compressor oil and oil filter change...... 435.9 Compressor Oil Flushing Procedure .......... 455.10 Coolant specifications ................................ 465.10.1 PARCOOL EG ...................................... 46
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PrefacePlease read the following instructions carefullybefore starting to use your compressor.It is a solid, safe and reliable machine, builtaccording to the latest technology. Follow theinstructions in this booklet and we guarantee youyears of troublefree operation.Always keep the manual available near the machine.In all correspondence always mention thecompressor type and serial number, shown on thedata plate.The company reserves the right to make changeswithout prior notice.
Table of contents1 Safety precautions ...................................... 1.1 Introduction .................................................. 1.2 General safety precautions ........................... 1.3 Safety during transport and installation ....... 1.4 Safety during use and operation................... 1.5 Safety during maintenance and repair........ 11.6 Tool applications safety ............................. 11.7 Specific safety precautions......................... 1
2 Leading particulars .................................. 12.1 General description .................................... 1
3 Main parts - Open Frame ........................ 13.1 Regulating system ...................................... 13.1.1 Overview................................................ 13.1.2 Air flow.................................................. 13.1.3 Oil system .............................................. 13.1.4 Pneumatic regulating system ................. 23.2 Electric system ........................................... 23.3 Markings and information labels ............... 2
4 Operating instructions ............................. 24.1 Transport and installation instructions ....... 24.1.1 Lifting instructions................................. 24.2 Night lights................................................. 24.3 Before starting ............................................ 24.4 Starting / Stopping...................................... 24.4.1 Operations overview .............................. 24.4.2 Battery switch ........................................ 24.4.3 Control panel.......................................... 24.4.4 Specific start procedure.......................... 2
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5.10.2 Handling PARCOOL EG....................... 475.11 Coolant check ............................................. 475.12 Topping up/replacing coolant..................... 475.12.1 Topping up without draining from
the cooling system.................................. 485.12.2 Topping up after limited quantity
draining from the cooling system........... 495.12.3 Replacing the coolant............................. 505.13 Cleaning coolers ......................................... 505.14 Battery care................................................. 525.14.1 Electrolyte .............................................. 525.14.2 Activating a dry-charged battery............ 525.14.3 Recharging a battery .............................. 525.14.4 Battery maintenance............................... 525.15 Compressor element overhaul .................... 52
6 Servicing procedures ................................ 536.1 Air filters engine / compressor ................... 536.1.1 Main parts .............................................. 536.1.2 Cleaning the dust trap ............................ 536.1.3 Replacing the filter element and
the safety cartridge ................................. 536.1.4 Air receiver............................................. 546.1.5 Safety valve............................................ 546.2 Fuel system................................................. 546.2.1 Priming instructions ............................... 546.2.2 Replacing filter elements........................ 556.2.3 Maintenance Quick action
fuel couplings ......................................... 55
7 Problem solving ........................................ 567.1 Oiltronix failure.......................................... 59
8 Available options ...................................... 6
9 Technical specifications ........................... 69.1 Torque values ............................................. 69.1.1 General torque values ............................ 69.1.2 Critical torque values ............................. 69.2 Compressor / engine specifications............ 69.2.1 Reference conditions.............................. 69.2.2 Limitations ............................................. 69.2.3 Performance data ................................... 69.2.4 Altitude unit performance curve ............ 69.2.5 Design data............................................. 6
10 Dataplate ................................................... 7
11 Legislation ................................................. 711.1 Parts, subjected to Pressure Equipment
Directive 97/23/EC, cat. II and above........ 711.2 Parts, subjected to cat. I and covered
by the Machine Directive 89/392/EC......... 711.3 Parts, subjected to art. I, paragraph 3.3 ...... 7
12 Disposal ..................................................... 712.1 General ....................................................... 712.2 Disposal of materials.................................. 7
13 Maintenance Log ...................................... 7
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Safety precautions
INTRODUCTION
The policy of Atlas Copco is to provide the users oftheir equipment with safe, reliable and efficientproducts. Factors taken into account are amongothers:- the intended and predictable future use of the
products, and the environments in which they areexpected to operate,
- applicable rules, codes and regulations,- the expected useful product life, assuming proper
service and maintenance,- providing the manual with up-to-date
information.Before handling any product, take time to read therelevant instruction manual. Besides giving detailedoperating instructions, it also gives specificinformation about safety, preventive maintenance,etc.Keep the manual always at the unit location, easyaccessible to the operating personnel.See also the safety precautions of the engine andpossible other equipment, which are separately sentalong or are mentioned on the equipment or parts ofthe unit.These safety precautions are general and somestatements will therefore not always apply to aparticular unit.Only people that have the right skills should beallowed to operate, adjust, perform maintenance orrepair on Atlas Copco equipment.
It is the responsibility of management to appointoperators with the appropriate training and skill foreach category of job.Skill level 1: OperatorAn operator is trained in all aspects of operating theunit with the push-buttons, and is trained to know thesafety aspects.Skill level 2: Mechanical technicianA mechanical technician is trained to operate the unitthe same as the operator. In addition, the mechanicaltechnician is also trained to perform maintenance andrepair, as described in the instruction manual, and isallowed to change settings of the control and safetysystem. A mechanical technician does not work onlive electrical components.Skill level 3: Electrical technicianAn electrical technician is trained and has the samequalifications as both the operator and the mechanicaltechnician. In addition, the electrical technician maycarry out electrical repairs within the variousenclosures of the unit. This includes work on liveelectrical components.Skill level 4: Specialist from the manufacturerThis is a skilled specialist sent by the manufacturer orits agent to perform complex repairs or modificationsto the equipment.In general it is recommended that not more than twopeople operate the unit, more operators could lead tounsafe operating conditions.
Take necessary steps to keep unauthorized personsaway from the unit and eliminate all possible sourcesof danger at the unit.When handling, operating, overhauling and/orperforming maintenance or repair on Atlas Copcoequipment, the mechanics are expected to use safeengineering practices and to observe all relevant localsafety requirements and ordinances. The followinglist is a reminder of special safety directives andprecautions mainly applicable to Atlas Copcoequipment.These safety precautions apply to machineryprocessing or consuming air. Processing of any othergas requires additional safety precautions typical tothe application and are not included herein.Neglecting the safety precautions may endangerpeople as well as environment and machinery:- endanger people due to electrical, mechanical or
chemical influences,- endanger the environment due to leakage of oil,
solvents or other substances,- endanger the machinery due to function failures.All responsibility for any damage or injury resultingfrom neglecting these precautions or by non-observance of ordinary caution and due care requiredin handling, operating, maintenance or repair, also ifnot expressly mentioned in this instruction manual, isdisclaimed by Atlas Copco.
To be read attentively and acted accordingly before towing, lifting, operating, performingmaintenance or repairing the compressor.
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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.
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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 unin a safe operating condition. Unit parts anaccessories must be replaced if missing ounsuitable for safe operation.
2 The supervisor, or the responsible person, shall aall times make sure that all instructions regardinmachinery and equipment operation anmaintenance are strictly followed and that thmachines with all accessories and safety devicesas well as the consuming devices, are in goorepair, free of abnormal wear or abuse, and arnot tampered with.
3 Whenever there is an indication or any suspiciothat an internal part of a machine is overheatedthe machine shall be stopped but no inspectiocovers shall be opened before sufficient coolintime has elapsed; this to avoid the risk ospontaneous ignition of oil vapour when air iadmitted.
4 Normal ratings (pressures, temperatures, speedsetc.) shall be durably marked.
5 Operate the unit only for the intended purpose anwithin its rated limits (pressure, temperaturespeeds, etc.).
6 The machinery and equipment shall be kept cleani.e. as free as possible from oil, dust or othedeposits.
7 To prevent an increase in working temperatureinspect and clean heat transfer surfaces (coolefins, intercoolers, water jackets, etc.) regularlySee the Preventive maintenance schedule.
8 All regulating and safety devices shall bmaintained with due care to ensure that thefunction properly. They may not be put out oaction.
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lifting beam shall be applied between hoist andload.
9 Never leave a load hanging on a hoist.10 A hoist has to be installed in such a way that the
object will be lifted perpendicular. If that is notpossible, the necessary precautions must be takento prevent load-swinging, e.g. by using twohoists, each at approximately the same angle notexceeding 30° from the vertical.
11 Locate the unit away from walls. Take allprecautions to ensure that hot air exhausted fromthe engine and driven machine cooling systemscannot be recirculated. If such hot air is taken inby the engine or driven machine cooling fan, thismay cause overheating of the unit; if taken in forcombustion, the engine power will be reduced.
12 Before moving the compressor, switch it off.13 If the warning light on the ABS module or in the
vehicle lights up, please contact Atlas Copco.
SAFETY DURING USE AND OPERATION
1 When the unit has to operate in a fire-hazardousenvironment, each engine exhaust has to beprovided with a spark arrestor to trap incendiarysparks.
2 The exhaust contains carbon monoxide which is alethal gas. When the unit is used in a confinedspace, conduct the engine exhaust to the outsideatmosphere by a pipe of sufficient diameter; dothis in such a way that no extra back pressure iscreated for the engine. If necessary, install anextractor. Observe any existing local regulations.Make sure that the unit has sufficient air intakefor operation. If necessary, install extra air intakeducts.
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SAFETY DURING TRANSPORT AND INSTALLATION
Transport of the unit has to be done by authorized/experienced people.When towing, lifting or transporting the compressorin any way, the battery switch must always be in the“OFF” position!To lift a unit, all loose or pivoting parts, e.g. doors andtow bar, shall first be securely fastened.Do not attach cables, chains or ropes directly to thelifting eye; apply a crane hook or lifting shacklemeeting local safety regulations. Never allow sharpbends in lifting cables, chains or ropes.Helicopter lifting is not allowed.It is strictly forbidden to dwell or stay in the risk zoneunder a lifted load. Never lift the unit over people orresidential areas. Lifting acceleration and retardationshall be kept within safe limits.1 Before towing the unit:
- ascertain that the pressure vessel(s) is (are)depressurized,
- check the tow bar, the brake system and thetowing eye. Also check the coupling of thetowing vehicle,
- check the towing and brake capability of thetowing vehicle,
- check that the tow bar, jockey wheel or standleg is safely locked in the raised position,
- ascertain that the towing eye can swivel freelyon the hook,
- check that the wheels are secure and that thetyres are in good condition and inflatedcorrectly,
- connect the signalisation cable, check all lightsand connect the pneumatic brake couplers,
- attach the safety break-away cable or safetchain to the towing vehicle,
- remove wheel chocks, if applied, andisengage the parking brake,
- check wether springs on wheelchocks armissing or broken.
2 To tow a unit use a towing vehicle of amplcapacity. Refer to the documentation of thtowing vehicle.
3 If the unit is to be backed up by the towinvehicle, disengage the overrun brake mechanism(if it is not an automatic mechanism).
4 Never exceed the maximum towing speed of thunit (mind the local regulations).
5 Place the unit on level ground and apply thparking brake before disconnecting the unit fromthe towing vehicle. Unclip the safety break-awacable or safety chain. If the unit has no parkinbrake or jockey wheel, immobilize the unit bplacing chocks in front of and/or behind thwheels. When the tow bar can be positionevertically, the locking device must be applied ankept in good order. The unit must always be usedparked/stored in a non publicly accessible arealocked away from access by unauthorizepersons.
6 To lift heavy parts, a hoist of ample capacitytested and approved according to local safetregulations, shall be used.
7 Lifting hooks, eyes, shackles, etc., shall never bbent and shall only have stress in line with thedesign load axis. The capacity of a lifting devicdiminishes when the lifting force is applied at aangle to its load axis.
8 For maximum safety and efficiency of the liftinapparatus all lifting members shall be applied anear to perpendicular as possible. If required,
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17 Noise, even at reasonable levels, can causeirritation and disturbance which, over a longperiod of time, may cause severe injuries to thenervous system of human beings. When the soundpressure level, at any point where personnelnormally has to attend, is:- below 70 dB(A): no action needs to be taken,- above 70 dB(A): noise-protective devices
should be provided for people continuouslybeing present in the room,
- below 85 dB(A): no action needs to be takenfor occasional visitors staying a limited timeonly,
- above 85 dB(A): room to be classified as anoise-hazardous area and an obvious warningshall be placed permanently at each entranceto alert people entering the room, for evenrelatively short times, about the need to wearear protectors,
- above 95 dB(A): the warning(s) at theentrance(s) shall be completed with therecommendation that also occasional visitorsshall wear ear protectors,
- above 105 dB(A): special ear protectors thatare adequate for this noise level and thespectral composition of the noise shall beprovided and a special warning to that effectshall be placed at each entrance.
18 The unit has parts, which may be accidentallytouched by personnel, of which the temperaturecan be in exess of 80 °C (176 °F). The insulationor safety guard, protecting these parts shall not beremoved before the parts have cooled down toroom temperature.
19 Never operate the unit in surroundings wherethere is a possibility of taking in flammable ortoxic fumes.
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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-blastinor will be connected to a common compressed-asystem, fit an appropriate non-return valve (checvalve) between compressor outlet and thconnected sand-blasting or compressed-asystem. Observe the right mounting positiondirection.
11 Before removing the oil filler plug, ensure that thpressure is released by opening an air outlevalve.
12 Never remove a filler cap of the cooling watesystem of a hot engine. Wait until the engine hasufficiently cooled down.
13 Never refill fuel while the unit is running, unlesotherwise stated in the Atlas Copco InstructioBook (AIB). Keep fuel away from hot parts sucas air outlet pipes or the engine exhaust. Do nosmoke when fuelling. When fuelling from aautomatic pump, an earthing cable should bconnected to the unit to discharge statielectricity. Never spill nor leave oil, fuel, coolanor cleansing agent in or around the unit.
14 All doors shall be shut during operation so as noto disturb the cooling air flow inside thbodywork and/or render the silencing leseffective. A door should be kept open for a shoperiod only e.g. for inspection or adjustment.
15 Periodically carry out maintenance workaccording to the maintenance schedule.
16 Stationary housing guards are provided on arotating or reciprocating parts not otherwisprotected and which may be hazardous tpersonnel. Machinery shall never be put intoperation, when such guards have been removedbefore the guards are securely reinstalled.
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6 Make sure that no tools, loose parts or rags are leftin or on the machine. Never leave rags or looseclothing near the engine air intake.
7 Never use flammable solvents for cleaning (fire-risk).
8 Take safety precautions against toxic vapours ofcleaning liquids.
9 Never use machine parts as a climbing aid.10 Observe scrupulous cleanliness during
maintenance and repair. Keep away dirt, coverthe parts and exposed openings with a clean cloth,paper or tape.
11 Never weld on or perform any operationinvolving heat near the fuel or oil systems. Fueland oil tanks must be completely purged, e.g. bysteam-cleaning, before carrying out suchoperations. Never weld on, or in any way modify,pressure vessels. Disconnect the alternator cablesduring arc welding on the unit.
12 Support the tow bar and the axle(s) securely ifworking underneath the unit or when removing awheel. Do not rely on jacks.
13 Do not remove any of, or tamper with, the sound-damping material. Keep the material free of dirtand liquids such as fuel, oil and cleansing agents.If any sound-damping material is damaged,replace it to prevent the sound pressure level fromincreasing.
14 Use only lubricating oils and greasesrecommended or approved by Atlas Copco or themachine manufacturer. Ascertain that theselected lubricants comply with all applicablesafety regulations, especially with regard toexplosion or fire-risk and the possibility ofdecomposition or generation of hazardous gases.Never mix synthetic with mineral oil.
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20 If the working process produces fumes, dust orvibration hazards, etc., take the necessary steps toeliminate the risk of personnel injury.
21 When using compressed air or inert gas to cleandown equipment, do so with caution and use theappropriate protection, at least safety glasses, forthe operator as well as for any bystander. Do notapply compressed air or inert gas to your skin ordirect an air or gas stream at people. Never use itto clean dirt from your clothes.
22 When washing parts in or with a cleaning solvent,provide the required ventilation and useappropriate protection such as a breathing filter,safety glasses, rubber apron and gloves, etc.
23 Safety shoes should be compulsory in anyworkshop and if there is a risk, however small, offalling objects, wearing of a safety helmet shouldbe included.
24 If there is a risk of inhaling hazardous gases,fumes or dust, the respiratory organs must beprotected and depending on the nature of thehazard, so must the eyes and skin.
25 Remember that where there is visible dust, thefiner, invisible particles will almost certainly bepresent too; but the fact that no dust can be seenis not a reliable indication that dangerous,invisible dust is not present in the air.
26 Never operate the unit at pressures or speedsbelow or in excess of its limits as indicated in thetechnical specifications.
SAFETY DURING MAINTENANCE AND REPAIR
Maintenance, overhaul and repair work shall only bcarried out by adequately trained personnel; required, under supervision of someone qualified fothe job.1 Use only the correct tools for maintenance an
repair work, and only tools which are in goocondition.
2 Parts shall only be replaced by genuine AtlaCopco replacement parts.
3 All maintenance work, other than routinattention, shall only be undertaken when the unis stopped. Steps shall be taken to preveninadvertent starting. In addition, a warning sigbearing a legend such as ”work in progress; dnot start” shall be attached to the startinequipment. On engine-driven units the battershall be disconnected and removed or thterminals covered by insulating caps. Oelectrically driven units the main switch shall blocked in open position and the fuses shall btaken out. A warning sign bearing a legend sucas ”work in progress; do not supply voltage” shabe attached to the fuse box or main switch.
4 Before dismantling any pressurized componenthe compressor or equipment shall be effectivelisolated from all sources of pressure and the entirsystem shall be relieved of pressure. Do not relon non-return valves (check valves) to isolatpressure systems. In addition, a warning sigbearing a legend such as ”work in progress; dnot open” shall be attached to each of the outlevalves.
5 Prior to stripping an engine or other machine oundertaking major overhaul on it, prevent amovable parts from rolling over or moving.
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15 Protect the engine, alternator, air intake filter,electrical and regulating components, etc., toprevent moisture ingress, e.g. when steam-cleaning.
16 When performing any operation involving heat,flames or sparks on a machine, the surroundingcomponents shall first be screened with non-flammable material.
17 Never use a light source with open flame forinspecting the interior of a machine.
18 Disconnect –battery-clamp before startingelectrical servicing or welding (evt. turn battery-switch in “off” position).
19 When repair has been completed, the machineshall be barred over at least one revolution forreciprocating machines, several revolutions forrotary ones to ensure that there is no mechanicalinterference within the machine or driver. Checkthe direction of rotation of electric motors whenstarting up the machine initially and after anyalteration to the electrical connection(s) or switchgear, to check that the oil pump and the fanfunction properly.
20 Maintenance and repair work should be recordedin an operator’s logbook for all machinery.Frequency and nature of repairs can reveal unsafeconditions.
21 When hot parts have to be handled, e.g. shrinkfitting, special heat-resistant gloves shall be usedand, if required, other body protection shall beapplied.
22 When using cartridge type breathing filterequipment, ascertain that the correct type ofcartridge is used and that its useful service life isnot surpassed.
23 Make sure that oil, solvents and other substancelikely to pollute the environment are properldisposed of.
24 Before clearing the unit for use after maintenancor overhaul, check that operating pressurestemperatures and speeds are correct and that thcontrol and shutdown devices function correctly
TOOL APPLICATIONS SAFETY
Apply the proper tool for each job. With thknowledge of correct tool use and knowing thlimitations of tools, along with some common sensemany accidents can be prevented.Special service tools are available for specific joband should be used when recommended. The use othese tools will save time and prevent damage tparts.
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9 (Pressure) vessel maintenance is to be performedby Atlas Copco.
Safety valvesOperating & MaintenanceOnly trained and technically competent personnelshould consider overhaul, re-set or performancetesting of safety valves.The safety valve is supplied with either a lead securityseal or crimped cover to deter unauthorised access tothe pressure regulation device.Under no circumstances should the set pressure of thesafety valve be altered to a different pressure than thatstamped on the valve without the permission of theinstallation designer.If the set pressure must be altered then use onlycorrect parts supplied by Seetru and in accordancewith the instructions available for the valve type.Safety valves must be frequently tested and regularlymaintained.The set pressure should be periodically checked foraccuracy.When fitted, the lifting device should be operated atpressures not less than 75% of the set pressure toensure free and easy movement of internal parts.The frequency of tests is influenced by factors such asthe severity of the operating environment andaggressiveness of the pressurised medium.Soft seals and springs should be replaced as part of themaintenance procedure.Do not paint or coat the installed safety valve (see alsoPreventive maintenance schedule).
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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 a
separator and is designed to hold compressed afor the following application:- pressure vessel for compressor,- medium AIR/OIL,- and operates as detailed on the data plate of th
vessel:- the maximum working pressure ps in bar (psi- the maximum working temperature Tmax i
°C (°F),- the minimum working temperature Tmin in °C
(°F),- the capacity of the vessel V in l (US gal, Im
gal, cu.ft).2 The pressure vessel is only to be used for th
applications as specified above and in accordancwith the technical specifications. Safety reasonprohibit any other applications.
3 National legislation requirements with respect tre-inspection must be complied with.
4 No welding or heat treatment of any kind ipermitted to those vessel walls which are exposeto pressure.
5 The vessel is provided and may only be used witthe required safety equipment such amanometer, overpressure control devices, safetvalve, etc.
6 Draining of condensate shall be performed dailwhen vessel is in use.
7 Installation, design and connections should not bchanged.
8 Bolts of cover and flanges may not be used foextra fixation.
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Leading particularsGENERAL DESCRIPTION
The XRXO 667 Cd - XRXO 1400 CD7 is a two-stage,oil-injected screw compressor, built for a nominaleffective working pressure of 30 bar (435 psi).The XRVO 727 Cd - XRVO 1550 CD7 is a two-stage,oil-injected screw compressor, built for a nominaleffective working pressure of 25 bar (365 psi).
EngineThe compressors are driven by a 6 cilinder in-lineliquid-cooled diesel engine.The engine’s power is transmitted to the compressorelement through a heavy-duty coupling.
CompressorThe compressor casing houses two screw-type rotors,mounted on ball and roller bearings. The male rotor,driven by the engine, drives the female rotor. Thecompressor delivers pulsation-free air.Injected oil is used for sealing, cooling andlubricating purposes.
Compressor oil systemThe oil is boosted by air pressure. The system has noil pump.The oil is removed from the air, in the air/oil vessel afirst by centrifugal force, secondly through the oseparator element.The vessel is provided with an oil level indicator.
RegulationThe compressor is provided with a single or duapressure pneumatic regulating system and a blow-ofvalve which is integrated in the unloader assemblyThe valve is closed during operation by air receivepressure and opens by air receiver pressure via thcompressor element when the compressor is stoppedWhen the air consumption increases, the air receivepressure will decrease and vice versa.This receiver pressure variation is sensed by thregulating valve which, by means of control air to thunloader and an electronic engine speed regulatomatches the air output to the air consumption. The areceiver pressure is maintained between the preselected working pressure and the correspondinunloading pressure.
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- 15 -
Cooling systemThe engine is provided with a liquid-cooler andintercooler and the compressor is provided with an oilcooler.The cooling air is generated by a fan, driven by theengine.The fan can be a “pull” or “push” type fan. Anaftercooler can only be installed on a unit with a“pull” fan.
Safety devicesA thermal shut-down sensor protects the compressoragainst overheating. The air receiver is provided witha safety valve.The engine is equipped with low oil pressure and highcoolant temperature shut-down sensors.The electric system is equipped with a 24V mainswitch.
Frame and axlesThe compressor/engine unit is supported by rubberbuffers in a sturdy frame.The frame is equipped with a bottom plate forcollecting spilled fluids. For transport at the site theunit is equipped with a lifting beam (crane lifting) andforklift openings. For fixing the unit on site or on alorry fixing holes are equipped at the corners.
Serial number
The serial number (1) on top of the beam near the datplate. It is also mentioned on the data plate (2) aninside the control box.
Control panelThe control panel grouping the air pressure gaugecontrol switch etc., is placed at the left hand/ rear encorner.
Data plateThe compressor is furnished with a data plate (2showing the product code, the unit serial number anthe working pressure (see chapter Dataplate).
(2) (1)
- 16 -
Main parts - Open Frame
- 17 -
Reference NameA AlternatorAFce Air Filter (compressor element)AFe Air Filter (engine)AOV Air Outlet ValvesAR Air ReceiverB BatteryCEhp Compressor Element (High
Pressure)CElp Compressor Element (Low
Pressure)CP Control PanelDPar Drain Plug Air ReceiverDSE Dipstick Engine OilE EngineEP Exhaust PipeF FanFCc Filler Cap (coolant)FCe Filler Cap (engine oil)FF Fuel FilterFFp Fuel Pre FilterFPco Filler Plug (compressor oil)MPV Minimum Pressure ValveOC Oil Cooler
Reference NameOFce Oil Filter (compressor element)OFe Oil Filter (engine)OLG Oil Level GaugeR RadiatorRV Regulating ValveSL Scavenge LineSM Starting MotorSOV Solenoid ValveSV Safety ValveUV Unloading Valve
Reference NameAFce Air Filter (compr. element)AFe Air Filter (engine)AFS Air Filter SwitchAOV Air Outlet ValvesAR/OS Air Receiver / Oil SeparatorBOV Blow Off ValveBVof Bypass Valve oil filterC CouplingCBE Cubicle for Electrical devicesCEhp Compressor Element (high pressure)CElp Compressor Element (low pressure)CU Control UnitDP Drain PlugE EngineF FanLV Loading ValveMPV Minimum Pressure ValveOC Oil CoolerOFce Oil Filter (compressor element)OFe Oil Filter (engine)OSV Oil Stop ValveOT OiltronixPS Pressure Sensor
- 18 -
REGULATING SYSTEM
OVERVIEW
(OC)(F)(UA)(TV)(BOV)(E)
(CE lp)
(CE hp)
(OSV)
(TS)
(PS)
(CBE)
(CU)
(DP)(LV)(RV)
(MPV)(AOV)
(SL)
(BVof)
(SV)
(AR/OS)(WPS)(TBV)
(OFce)(OT)
(OFe)
(SC)
(AFe)(AFce)
(AFS)
(C)
eto
iril
f
ee,
nilea
),r
OIL SYSTEM
The lower part of the air receiver (AR) serves as oiltank.Air pressure forces the oil from the air receiver/oilseparator (AR/OS) through the oil cooler (OC), the oilfilters (OF) and the oil stop valve (OSV) to thecompressor element (CEhp CElp).When the compressor is stopped and / or there is nopressure in the system, the oil stop valve (OSV)prevents the oil from flowing back into thecompressor element.The thermostatic by-pass valve (TBV) starts openingwhen the oil temperature is 40°C (104°F).The compressor element has an oil gallery in thebottom of its casing. The oil for rotor lubrication,cooling and sealing is injected through holes in thegallery.Lubrication of the bearings is ensured by oil injectedinto the bearing housings.The injected oil, mixed with the compressed air,leaves the compressor element and re-enters the airreceiver, where it is separated from the air asdescribed in section Air flow. The oil that collects inthe bottom of the oil separator element is returned tothe system through a scavenging line (SL), which isprovided with a flow restrictor.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).
- 19 -
AIR FLOW
Air drawn through the airfilter (AFce) into thcompressor element (CEhp CElp) is compressed. Athe element outlet, compressed air and oil pass intthe air receiver/oil separator (AR/OS).A check valve prevents blow-back of compressed awhen the compressor is stopped. In the air receiver/oseparator (AR/OS), most of the oil is removed fromthe air/oil mixture.The oil collects in the receiver and on the bottom othe separator element.The air leaves the receiver via a minimum pressurvalve (MPV) which prevents the receiver pressurfrom dropping below the minimum working pressureeven when the air outlet valves are open (specified isection Limitations). This ensures adequate oinjection and prevents oil consumption. Thminimum pressure valve (MPV) also functions as check valve.The system comprises temperature sensors (TSpressure sensors (PS) and a working pressure senso(WPS).
Reference NameRV Regulating ValveSC Safety CartridgeSL Scavenge LineSV Safety ValveTBV Thermostatic Bypass ValveTS Temperature SensorTV Throttle ValveUA Unloader AssemblyWPS Working Pressure Sensor
- 20 -
PNEUMATIC REGULATING SYSTEM
(UA)(TV)
(BOV)
(CE lp)
(CE hp)
(RV)
(AR/OS)
ireerdg4
f)d
hreee
d
- 21 -
The compressor is provided with a pneumaticregulating system and a blow-off valve (BOV) whichis integrated in the unloader assembly (UA). Thevalve is closed during operation by outlet pressure ofthe compressor element and opens by air receiverpressure when the compressor is stopped.When the air consumption increases, the air receiverpressure will decrease and vice versa. This receiverpressure variation is sensed by the regulating valve(RV) which, by means of control air to the unloaderassembly (UA), matches the air output to the airconsumption. The air receiver pressure is maintainedbetween the pre-selected working pressure and thecorresponding unloading pressure.When starting the compressor, the throttle valve (TV)is kept closed via receiver pressure. The compressorelement (CEhp CElp) takes in air and pressure buildsup in the receiver (AR). The throttle valve (TV) isclosed. The air output is controlled from maximumoutput (100%) to no output (0%) by:1. Speed control of the engine between maximum
load speed and unloading speed (the output of a screw compressor is proportional to the rotating speed).
2. Air inlet throttling.If the air consumption is equal to or exceeds themaximum air output, the engine speed is held atmaximum load speed and the throttle valve (TV) isfully open.
If the air consumption is less than the maximum aoutput, air receiver pressure increases and thregulating valve supplies control air to throttle valv(TV) to reduce the air output and holds air receivepressure between the normal working pressure anthe corresponding unloading pressure. Unloadinpressure = normal working pressure + 1 bar (14.50psi).When the air consumption is resumed, the blow ofvalve (BOV) closes and the throttle valve (TVgradually opens the air intake and the electronic speeregulator increases the engine speed.The construction of the regulating valve (RV) is sucthat any increase (decrease) of the air receivepressure above the pre-set valve opening pressurresults in a proportional increase (decrease) of thcontrol pressure to the throttle valve and thelectronic speed regulator.Part of the control air is vented to atmosphere, anany condensate discharged, through the vent holes.
a2
24
b2
24M
b2
24M
b2
25M
a5
47 a6
22 a7
21 a8
20a3
99
a3
28
b2 27M
b2 24M
a6
29
a5
4
a5
5
a5
6
a5
8
a6
18
a5
11
a5
9
a5
10
a5a5
31
a4
34
a5D05 a3H1
0 a8
L01
a3
28
a7
T01
a8
L02
a8
L03
a3
H08
a7
T05
a4V07
a5D06
a4V05
a4V04
a3
H06
b2 24M
a6 19 a6 19a6 19
a6
19
a5
30
a3
2
a3
1
a3
33
a3
32
a3 BOV
a5 47 b3
REF
b3 19
b6 19 b6 19a6 19 a6 19 a6 19
a9 ST4a5 ST
3a0
ST2a2
ST1
a6 19a6 19
a6
19a6
19a6
19
a0ST47
a5ST46 a2
ST45
a0 ST47a5 ST
46a2
ST45
a2
24
a3
28a3
28
a3 28a8
20
7
2122
Y4
N4
28
56
1 3 551356
462612
473734
1432
8765
driver
stepp
er
A+A-B+B-
M3
S1
Y3
3087
K5 S48586 K4
A13: L-OUT3 (spare)
B5: D-IN05 (opt)C14: H-OUT10 (opt)
H-OUT07: B15
V-IN06: B6
(opt) T-IN06: C10
C4: D-IN07
B14: Eng PAC
D-IN04: B4
A11: L-OUT01 (opt)
C7: V-IN04 (spare)C6: V-IN05 (spare)C3: D-IN06 (spare)C2: V -IN07 (spare)
C15: H-OUT06 (spare)
A12: L-OUT2 (spare)A9: T-IN01 (spare)
H-OUT05: D15H-OUT04: D16
GND: D1
B10: T-IN05 (spare)
T-IN04: B9
A15: H-OUT08 (spare)
V-IN03: B7
N1
T-IN03: D9T-IN02: C9
V-IN01: A7
H-OUT02: B16
D-IN01: A3
D-IN02: A4
H-OUT03: C16
B1: Em Stop A1: Supply
D13: CAH GD12: CAN LD11: CAN H
V-IN02: D75V: B8
GND SENS: C8
D-IN03: B3
A16: Compr PAC
CCM
S1
(9822 1016 16 - XRXO 667 / XRVO 727)
- 22 -
ELECTRIC SYSTEM
l0 24
a0
18
a0
NA4
a0
NA3
a0 NA2
a0 NA1
a6 19f6 19l0 19
l0 19
l0 24
f0 24
f0 3
f2 24
f6 19
b6 19
b2 24Me
b6 19
b2 24M
b2 24M
b2 24M
l0 f2 24f0 2424 b2
24
b2 24 b2
24
b2
24
b2
24
b2 24Me
b2
24Md
b2
24Mc
b2
24Mb
b2
24Ma
b2
24Md
b2
24Mc
b2
24Mb
b2
24Ma
b6
19
b6
19
b6
19
b6
19
b6
19
b6
19
b6
19
b6
19
a4
36 a535
a547 a622 a721 a820 a399
a6 19
a3
28
a8
20
a7
21
a6
22
a5
35
a4
36
b6 19 a6 19
a7
21
a9
20
b2
24
a2 48a6 19
a6
53
a6
52
a1
49
aa6a2
48
a2
48
a2
48
a2
25
M
19
N3
B1CAT Diagnostic
S3
10AF3
2
4
1
3
sensorCombo
10A
F4
BNBNBU
BU SS
5533
51 50 42
57 223
controllerOiltronix
10A
F2d10A
F2c10A
F2b15AF1
N7 N6
COM4COM3COM2COM1NA1NA2NA3NA4 ALIM
GND
remote
contr
olRE
CEIVE
R
7213465
remote
conn
.CC
M
M2
AB
GFCE DX1
S2
10A
F2a
CAT ADEM A4J1/P1�-61
J1/P1�-55
J1/P1�-48
J1/P1-10
J1/P1-70
J1/P1-9J1/P1-8
J1/P1�-69
J1/P1�-65
J1/P1�-63
J1/P1�-53
N2
J1/P1-42J1/P1-34J1/P1-50
J1/P1�-52
ECM
K1
24VDC
W+G3 B+
B-D+
K0 M1
MK0
G2 -+
G1 -+
X1 ECM Diagnostic connectorY1 Solenoid valve, LoadY2 Solenoid valve, Blow-off
OPTIONAL:K4 Relay, Inlet Shutdown ValveK5 Relay, EtherstartN6 Wireless receiverN7 CCM Remote connectorS4 Switch, Dual pressureTT4 Temperature sensor, Aftercooler temperatureY3 Solenoid valve, Inlet Shutdown ValveY4 Solenoid valve, Dual pressure
Wire cross sections:a 1 mm2
b 1.5 mm2
f 10 mm2
l 95 mm2
Wire colors:0 black1 brown2 red3 orange4 yellow5 green6 blue7 purple8 grey9 white
- 23 -
STANDARD:B1 Combo sensorF1 Circuit breaker 15AF2 Circuit breakers 10A, ECMF3 Circuit breaker 10A, Fuel priming pumpF4 Circuit breaker 15A, OiltronixG1 BatteryG2 BatteryG3 Charging alternatorH4 Flasher lightH6 HornK0 Relay, Starter solenoidK1 Relay, StarterLS1 Level switch, Coolant level warningLS2 Level switch, Coolant level shutdownM1 Starter motorM2 Fuel priming pumpM3 Stepper motorN1 Compressor Control ModuleN2 Engine Control ModuleN3 Oiltronix control moduleN4 Stepper motor driverPS1 Pressure switch, AirfilterPS2 Pressure switch, AirfilterPT1 Pressure sensor, Vessel pressurePT2 Pressure sensor, Regulating pressurePT3 Pressure sensor, Interstage pressurePT4 Pressure sensor, Oilstop valve pressureS1 Emergency stopS2 Battery switchS5 Proximity switchS6 Proximity switchTT1 Temperature sensor, LP element temperatureTT2 Temperature sensor, HP element temperatureTT3 Temperature sensor, Ambient temperature
b2 27M
b2 24M
a6
19
a6
19
a3
28a4
34a3
28a5
31
a6
29
a5
4
a5
5
a5
6
a5
8
a9 29a3 28a5 4
a6 18
a9 29
a3 28
a5 5
a6 18
a9 29
a3 28
a5 6
a6 18
a9 29
a3 28
a5 8
a6 18
a6 18a6 18a6 18a6 18a6
18
a5
AC_T
a5
11
a5
10
a5
9
a5
11
a5
9
a5
10
a5
AC_T
a5
31
a4
34
a6
19
a5
30
a3
2
a3
1
a3
33
a3
32
a3 BOV a5 30
a4 7a3 2a3 1a3 33a3 32a3
BOV
b3 19
b6 19 a6 19a6 19a6 19a6 19a6 19a6 19a6 19a6 19
Y1Y2
P PS2
PT4SIGV-
V+ 5VDCV+ 24VDC
UP
TT4
19 8586
K1
LS1LS2
PT3SIGV-
V+ 5VDCV+ 24VDC
UP
PT2SIGV-
V+ 5VDCV+ 24VDC
UP
H6H4
H-OUT07: B15
V-IN06: B6
(opt) T-IN06: C10
D-IN04: B4
H-OUT05: D15H-OUT04: D16
GND: D1
T-IN04: B9
V-IN03: B7
T-IN03: D9T-IN02: C9
V-IN01: A7
H-OUT02: B16
D-IN01: A3
D-IN02: A4
H-OUT03: C16
B1: Em StopA1: Supply
V-IN02: D75 V: B8
GND SENS: C8
D-IN03: B3
CCM
P PS1
TT3
PT1SIGV-
V+ 5VDCV+ 24VDC
UP
TT2
TT1
- 24 -
MARKINGS AND INFORMATION LABELS
Dangerous outlet gases.
Danger, hot surface.
Electrocution hazard.
Atlas Copco synthetic compressor oil.
Atlas Copco mineral engine oil.
Manual.
Read the instruction manual before working on the battery.
Reset fuse.
On / off button.
Prohibition to open air valves without connected hoses.
Rotation direction.
Inlet.
Outlet.
Compressor oil drain.
Read the instruction manual before starting.
Service every 24 hours.
Warning! Part under pressure.
Do not stand on outlet valves.
Start-Stop indication of switch.
Do not run the compressor with open doors.
Lifting permitted.
Use diesel fuel only.
Aftercooler 2-way valve.
Ear protection.
Fork lifting permitted.
Don’t lift here.
Read the instruction manual before lifting.
Filler cap coolant.
Read the instruction manual before topping up with coolant.
Service point.
Circuit breaker.
Do not run the compressor when the baffles are not in the right position.
- 25 -
Operating instructionsTRANSPORT AND INSTALLATION INSTRUCTIONS
Safety precautions
Attention
Locate the rear-end of the compressor upwind, awayfrom contaminated wind-streams and walls. Avoidrecirculation of exhaust air from the engine and hotair from the cooler pack. This can cause overheatingand engine power decrease.The compressor oil lifetime will be shortened whenthe compressor inlet air is contaminated.For installation instructions refer to the separateinstallation manual.
LIFTING INSTRUCTIONS
To lift the compressor, use a lift truck or crane withsufficient capacity (weight: see indication onDataplate).See to it that the compressor will be lifted verticallyand remains level.
The operator is expected to apply allrelevant Safety precautions.
When moving, lifting or transporting thecompressor in any way, the batteryswitch must always be in the “OFF”position!Also switch off the preheater as this unitis directly connected to the batteries.
Lifting acceleration and retardationmust be kept within safe limits (max.2xg).Helicopter lifting is not allowed.Lifting is not allowed when the unit isrunning.
- 26 -
NIGHT LIGHTS
The night light circuit is equipped with a timer. Whenthe night lights are switched on, the timer is started.After a preset time (4 minutes) the night light will beswitched off automatically.
BEFORE STARTING
1. Before initial start-up, prepare battery for operation if not already done. See section Recharging a battery.
2. Check that the draining opening in the bottom plate is connected to a draining line.
3. With the compressor standing level, check the level of the engine oil. Add oil, if necessary, to the upper mark on dipstick. Also check the engine coolant level. Consult the Engine Operation Manual for the type of coolant and type and viscosity grade of the engine oil.
4. Remove the air receiver drain plug (1), see figure, and open the valve to drain possible condensate. Close the valve when oil comes out and reinstall the drain plug. The interval between draining operations may be determined by experience, as the amount of condensate depends on the operating condition.
(1)
Before draining, ensure that thepressure is released.
- 27 -
5. Check the level of the compressor oil. See section Check compressor oil level. The pointer of oil level gauge (OLG) should register in the green range. Add oil if necessary. See section Compressor oil for the oil to be used.
6. Connect the supply and return hose to the fuel nipples at the fuel funnel. Move the lever of the fuel selection supply valve downwards.
7. Drain any water and sediment from the fuel filters until clean fuel flows from the drain cock.
8. Empty the dust trap of each air filter (AF). See section Replacing the filter element and the safety cartridge.
9. Clogged air filter(s) will be indicated on the display of the control panel. If indicated, replace the filter elements.
10. Check coolant level in engine coolant top tank integrated in radiator. Top up, if necessary. Consult the Engine Operation Manual for coolant specifications.
11. Attach the air line(s) to the closed air outlet valve(s).
12. Use hoses with suitable pressure rating and fit for the environmental conditions. Always install the pull relief (2), see figure. Inspect hoses and connections daily.
Before removing oil filler plug (FP),ensure that the pressure is released byopening an air outlet valve.
No external force may be applied to theair outlet valve(s), e.g. by pulling hosesor by connecting equipment directly tothe valve(s).
(1) (2)
- 28 -
STARTING / STOPPING
Safety precautions
OPERATIONS OVERVIEW
It is possible to control the compressor locally withthe Control Box, or with software running on a PCwith a CAN interface (PC Control Mode).The way one ends up in each status can differ fromhow the Control Box is controlled, but the function ofeach status stays the same.When reading this document, mind the differencebetween a status and a procedure. A status is a state inthe Control Box's operation. A procedure is an actionexecuted by the Control Box.Example: The Stopping procedure is executed in theStopping status, the Start Failure status and theShutdown status.
Regularly carry out following checks:1. That the regulating valve (RV) is correctly
adjusted, i.e. starts decreasing the engine speed when reaching the preset working pressure in the receiver.
2. Check the air outlet temperature of the compressor element.
3. Check the engine oil pressure, the coolant temperature and display of control box.
4. Avoid the engine running out of fuel. Nevertheless, if this happens, fill the external fuel tank and prime the fuel system to speed up starting (see section Specific start procedure).
BATTERY SWITCH
The compressor is equipped with a battery switch.When the compressor is not in use this switch mustalways be in the “OFF” position.It is not allowed to use this switch as an emergencyswitch or for stopping the compressor. It will causedamage in the control unit when using this switch forstopping.Always first shut off the control unit and wait until thedisplay is dark before switching the battery switch toposition “OFF”.
Do not disconnect power supply tocontrol box in any way when the controlbox is switched on. This will causememory loss.Do not switch off the circuit breakerwhen the control box is switched on. Thiswill cause memory loss.
When the compressor is put in operationfor the first time and after running out offuel or changing the fuel filter, follow thespecific start procedure as described insection Specific start procedure.
Always wear hearing protection whenoperating the unit.
Please be aware that the (optional)preheater unit is still “live” with thebattery switch in “OFF” position.
SPECIFIC START PROCEDURE
Follow this start procedure when the compressor isput in operation for the first time and after running outof fuel or changing the fuel filter.• Switch on the battery switch.• Push the toggle switch (1) “up” and hold it for
about 5 seconds. After releasing it, it will return to its “down” position.
• Switch the “ON/OFF” switch to position ”ON”. The instrument panel will now perform a brief selftest.
• Push the start button (I) and the starter motor will automatically try to start the engine.
If the engine fails to start, switch the “ON/OFF”switch to “OFF” again and repeat steps 2, 3 and 4.
(1)
- 29 -
CONTROL PANEL
(1)(2)
(3)(4)
(5)
(F1)
(F2)
(O)
(I)
(ON/OFF)
Reference Name1 Emergency stop2 Display (4 rows, 40 characters / row)3 Pressure gauge4 Arrow Up button5 Arrow Down button6 Fuel level gaugeF1 F1 Function buttonF2 F2 Function button0 Stop buttonI Start buttonON/OFF Power ON/OFF switch
- 30 -
POWER ON / OFF
Switch on the battery switch.Switch the machine on by switching the “ON/OFF”switch to the position “ON”. The instrument panelwill now perform a brief selftest.The display will show:
By pressing the button “F1”, the user goes to theINFO status.
STARTING
Press the button “I”. During the starting procedure thedisplay will show:
The system will automatically make 1 attempt to startthe engine. The attempt will be indicated on thedisplay as: '1/1'.
If the engine failed to start the display will show thecause of the failure:
When the stopping procedure has ended, the timemessage disappears and the F1 function appears(Reset). The display will show:
(F1)
(ON/OFF)
Do not disconnect power supply duringoperation.When disconnecting power supplyduring operation the user will beprompted to this by the next display.
(O)
(I)
To cool down the starting motor, thesystem will wait 1 minute before the nextattempt can be made, meanwhile do notleave the compressor.
- 31 -
WARMING UP
When the engine started, the Control Box executesfollowing Warm-up procedure.The engine keeps running at the Minimum RPM, untilthe Coolant Water Temperature has reached theWarm-up Temperature setting (40°C / 104°F).The display will show:
If the button “F1” is pressed during the warm-upprocess the engine will first warm-up beforeautomatically switching to LOAD.The display will show:
If the button “F1” is pressed after warming up, thecompressor immediately will enter the LOAD status.The pressure will rise till it the reaches setting.If the Warm-up Temperature has not been reachedafter 5 minutes, the Warm-up procedure will beended, and the Control Box will proceed to the NOTLOADED status.
After warming up the engine will run idle.The engine rpm is shown on the display.The display will show:
or
For entering the LOAD status the button “F1” has tobe pressed.
LOADING
By pressing the button “F1” the compressor will beloaded.The pressure will rise till it reaches the setting.
The engine rpm is shown on the display.The display will show:
The setting of the regulating valve withshut valves should be 2 bar (29 psi)higher than the required workingpressure.
(F1)
.l
.
- 32 -
When the compressor is shut down because ofexceeding a parameter setting (e.g. compressortemperature) the display shows:
and than:
After the stopping procedure has ended press F1 tocontinue.Restarting before the parameter is within its limits isimpossible because of the parameter check before thecranking procedure.
STOPPING
To turn off the compressor first press the button “0”The engine will run some time at min. speed to coodown and will stop finally. The remaining time is shown in the display:
Meanwhile the air receiver is depressurised.Switch the “ON/OFF” switch to the position “OFF”Wait until the display is dark.Switch the battery switch in the “OFF” position.
(O)
(ON/OFF)
- 33 -
EMERGENCY STOP
When an emergency stop button (1) is pressed, powerto all outputs is terminated, by the emergency stopitself (hardware) as well as by the software.The display will show:
When the emergency stop button (1) is unlocked theoperator can reset the emergency stop by pressing thebutton “F1”.
INFO
In the Info status, the user gets information about theCompressor configuration and starting environment:
Following topics are displayed in the Options statusas an endless list. (scrolling down at the last topicdisplays the first, scrolling up at the first topicdisplays the last).Text in capitals is the text that appears on the display.(max 19 characters).
(1) (F1)
The emergency stop button is only to be used in emergency situations; not for stoppingprocedures.
(F1)
(F2)
The “F1” button enters a menu, or confirms a newparameter setting.To select a menu, the button function text is“F1:SELECT”.To go back, the button function text is “F2:BACK”.
If the “F1” button is pressed, the topic next to ">" isselected.For example, if the operator wishes to change thelanguage to "NEDERLANDS", he would press the“F1” button when "LANGUAGE" is next to ">".From there the operator has entered the languagemenu. The present value is displayed under“LANGUAGE”.Then he scrolls to "NEDERLANDS" and presses the“F1” button.The display will show:
- 34 -
The characters XXXX XXXX in the upper rightcorner stand for compressor type.
• COMPRESSOR TYPE
• CONTROL MODE
• BATTERY VOLTAGE
• AMBIENT TEMPERATURE
• SOFTWARE VERSION
• COMPR. SERIAL NR
• ENGINE SERIAL NR
• FLEET NR (Optional)
The “F2” button returns to “READY TO START”.
OPTIONS
The operator can select following settings:
• Language
• Pressure Units (Metric / Imperial)
• Temperature Units (Kelvin / °C / °F)
• Flow Units (Metric / Imperial)
• Service (confirming service taks)
• Horn at start (enable / disable Horn during Start Warning Time)
• Tests (activating certain tests)
• History (viewing shutdown history)
• Electric refuel pump
• Remote start
• Aftercooler and bypass
• Regulating system dual pressure no fuel expert
• Regulating system dual pressure fuel expert
e
n
r
fnod
s
Dual pressure system (option for XRXS only)The dual pressure system has two regulating valvesmarked with I and II and a switch at the rear forselecting the lower (I) or higher (II) workingpressure.Set the regulating valve (RV) marked with I at aworking pressure lower than the regulating valvemarked with II. This means the handle of RV I shouldbe scewed in less than the handle of RV II. Thispressure setting is very important. When doneotherwise the system will not work correctly.When RV I is set at a working pressure of maximum25 bar (363 psi), the rpm will increase to 1900 rpm(instead of 1800 rpm) to deliver more FAD at this“lower” pressure. RV I can be set at a pressure higherthan 25 bar (363 psi), but then there will be no speedincrease.
(1)
(2)
- 35 -
SERVICE TASK CONFIRMED
The following confirmation is displayed for 10seconds, or until the “F1” button is pressed.
When the display shows the Option status again theservice task that has been confirmed is no longerdisplayed (because it is confirmed).
SERVICE IN ADVANCE
When “SERVICE IN ADVANCE” is selected theuser enters a submenu.If the next standard service task is due within 50running hours, the user can choose “NEXT SERVICETASK”.
Next to the next standard service task all activcustom service tasks are always displayed.When a service task is selected (pressing the butto“F1”), this service task is triggered and confirmed.This confirmation is also displayed.When pressing the button “F2”, “EXIT”, the usegoes straight to “READY TO START”.
PRESSURE ADJUSTMENT
Single pressure systemThe working pressure is determined by the tension othe spring in the regulating valve (RV). This tensiocan be increased to raise the pressure and decreased tlower it by turning the adjusting wheel clockwise ananti-clockwise respectively.To adjust the normal working pressure, proceed afollows:1. Loosen the lock nut of the regulating valve.2. Release Regulating Valve (turn out).3. With the outlet valves (AOV) closed, adjust the
regulating valve (RV), until a pressure is reachedof nominal pressure + 2 bar (+ 29 psi).
4. Lock the regulating valve (RV) by fixing the locknut.
(F1)
(F2)
- 36 -
MaintenanceLIABILITY
The manufacturer does not accept any liability for anydamage arising from the use of non-original parts andfor modifications, additions or conversions madewithout the manufacturer’s approval in writing.
SERVICE PAKS
A Service Pak is a collection of parts to be used for aspecific maintenance task, e.g. after 50, after 500 andafter 1000 running hours.It guarantees that all necessary parts are replaced atthe same time keeping down time to a minimum.The order number of the Service Paks are listed in theAtlas Copco Parts List (ASL).
Use of service paksService Paks include all genuine parts needed fornormal maintenance of both compressor and engine.Service Paks minimize downtime and keep yourmaintenance budget low.Order Service Paks at your local Atlas Copco dealer.
SERVICE KITS
A service kit is a collection of parts to fit a specificrepair or rebuilding task.It guarantees that all necessary parts are replaced atthe same time which improves the uptime of the unit.The order numbers of the Service Kits are listed in theAtlas Copco Parts List (ASL).
STORAGE
Run the compressor regularly, e.g. twice a week, untilwarm.Load and unload the compressor a few times tooperate the unloading and regulating components.Close the air outlet valves after stopping.
SAFETY PRECAUTIONS
Contact Atlas Copco.
If the compressor is going to be storedwithout running from time to time,protective measures must be taken.
Before performing any maintenancejobs always put the battery switch in the“OFF” position. See section Batteryswitch.Always observe the applicable safetyprecautions. See section Safety duringmaintenance and repair.Please note that when the battery switchis off there can still be some parts live!
- 37 -
PREVENTIVE MAINTENANCE SCHEDULE
The schedule contains a summary of the maintenanceinstructions. Read the respective section before takingmaintenance measures.When servicing, replace all disengaged packings, e.g.gaskets, O-rings, washers.For engine maintenance refer to Engine OperationManual.
The maintenance schedule has to be seen as aguideline for compressors operating in a dustyenvironment typical to compressor applications.Maintenance schedule can be adapted depending onapplication, environment and quality of maintenance.
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.Service hours Initially at 50 h 250 h 1000 hCalendarial Daily Every 6 months YearlyService parts 2912 6075 05
PAK2912 6408 06
PAK
For 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 xDrain condensate (11) xCheck compressor oil level xCheck coolant level xEmpty air filter vacuator valves x(to be continued on page 38)
ally at 50 h 250 h 1000 hEvery 6 months Yearly
x x xx x x
x xx xx xx x
xxxxxx
x x xx
x xxx
x xx xx xx x
- 38 -
Maintenance schedule(continuation of page 37)
InitiDaily
Drain water from fuel filter xCheck electrolyte level and terminals of batteryCheck for leaks in air-, oil- or fuel system (2)Clean oil coolerClean radiatorClean intercoolerCheck alternator beltTest safety valve (10)Replace bleed-off valve unloaderClean oil stop valveCheck rubber flexibles (2)Check shut down switchesReplace oil separator elementAdjust fan V-belts (3)Replace compressor oil (1) (8)Replace compressor oil filter (6)Analyse coolant (9) (5)Replace air filter element (1)Replace engine oil (3) (4)Replace engine oil filter (3)Replace primary fuel filter (AC filter) (7)Replace fuel prefilter (3) (7)(to be continued on page 39)
- 39 -
Notes
Maintenance schedule(continuation of page 38)
Initially at 50 h 250 h 1000 hDaily Every 6 months Yearly
Replace fuel filter (3) (7) x xReplace engine inlet and outlet valves (3) (12) x xClean flow restrictor in oil scavenge line xExternal fuel connectionInspection by Atlas Copco Service Technician x
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 engine operation manual.4. 250 / 1000 hours is only valid when using PAROIL E.5. Check coolant every year. Change coolant every 5 years.6. Use Atlas Copco oil filters, with by-pass valve, as specified in the parts list.7. Replace the fuel filters regularly. Gummed or clogged filters mean fuel starvation and reduced
engine performance. The quality of the fuel determines the frequency of renewal.8. See section Oil specifications.9. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing
point:• 2913 0028 00 refractometer• 2913 0029 00 pH meter.
10. See section Safety valve.11. See section Before starting.12. The engine inlet and outlet valves initially need to be adjusted at 500 hours.
For interventions on the engine onrunning hours above 800 h we refer tothe engine operation manual.
Keep the bolts of the housing, the liftingeye, the towbar and the axle securelytightened.Refer to section Technical specificationsfor the torque values.
- 40 -
OIL SPECIFICATIONS
High-quality, mineral, hydraulic or synthesizedhydrocarbon oil with rust and oxidation inhibitorsanti-foam and anti-wear properties is recommended.
It is strongly recommended to use AtlasCopco branded lubrication oils for bothcompressor and engine.
Only use synthetic compressor oil.
Never mix synthetic with mineral oil.Remark:When changing from mineral tosynthetic oil (or the other way around),you will need to do an extra rinse:After doing the complete changeprocedure to synthetic oil, run the unitfor a few minutes to allow good andcomplete circulation of the synthetic oil.Then drain the synthetic oil again andfill again with new synthetic oil. To setcorrect oil levels, proceed as in normalinstruction.
COMPRESSOR OIL
Synthetic compressor oil PAROIL S
Synthetic compressor oil PAROIL Sxtreme
Liter US gal Order numbercan 5 1.3 1615 5950 01can 20 5.3 1615 5951 01barrel 210 55.2 1615 5952 01container 1000 264 1604 7422 00
Liter US gal Order numbercan 20 5.3 1630 0181 00barrel 210 55.2 1630 0180 00
The viscosity grade should correspond to the ambient temperature and ISO 3448, as follows:
Type of lubricant Compressor Enginebetween -25°C (-13°F) and +30°C (86°F) PAROIL S PAROIL Extrabetween -10°C (14°F) and +30°C (86°F) PAROIL S PAROIL Ebetween -10°C (14°F) and +50°C (122°F) PAROIL Sxtreme PAROIL E
oo'sar
tit
)d
nn.
PAROIL Extra is a Synthetic ultra high performancediesel engine oil with a high viscosity- index. AtlasCopco PAROIL Extra is designed to provideexcellent lubrication from start-up in temperatures aslow as -25°C (-13°F). PAROIL E is a mineral basedhigh performance diesel engine oil with a highviscosity- index. Atlas Copco PAROIL E is designedto provide a high level of performance and protectionin 'standard' ambient conditions as from -15°C(5°F).
- 41 -
ENGINE OIL
PAROIL from Atlas Copco is the ONLY oil testedand approved for use in all engines built into AtlasCopco compressors and generators.Extensive laboratory and field endurance tests onAtlas Copco equipment have proven PAROIL tomatch all lubrication demands in varied conditions. Itmeets stringent quality control specifications toensure your equipment will run smoothly andreliably.The quality lubricant additives in PAROIL allow forextended oil change intervals without any loss inperformance or longevity.PAROIL provides wear protection under extremeconditions. Powerful oxidation resistance, highchemical stability and rust- inhibiting additives helpreduce corrosion, even within engines left idle forextended periods.
PAROIL contains high quality anti-oxidants tcontrol deposits, sludge and contaminants that tend tbuild up under very high temperatures. PAROILdetergent additives keep sludge forming particles in fine suspension instead of allowing them to clog youfilter and accumulate in the valve/rocker cover area.PAROIL releases excess heat efficiently, whilsmaintaining excellent bore-polish protection to limoil consumption.PAROIL has an excellent Total Base Number (TBNretention and more alkalinity to control aciformation.PAROIL prevents Soot build-upPAROIL is optimized for the latest low emissioEURO -3 & -2, EPA TIER II & III engines running olow sulphur diesel for lower oil and fuel consumption
Synthetic engine oil PAROIL Extra
Mineral engine oil PAROIL E
Liter US gal Order numbercan 5 1.3 1604 6060 00can 20 5.3 1604 6059 00
Liter US gal Order numbercan 5 1.3 1615 5953 00can 20 5.3 1615 5954 00barrel 210 55.2 1615 5955 00container 1000 264 1630 0096 00
- 42 -
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 compressor standing horizontal, check thelevel of the compressor oil.The pointer of the oil level gauge (1) must register inthe upper extremity of the green range. Add oil ifnecessary.
Before removing the oil filler plug (2),ensure that the pressure is released byopening an air outlet valve (3).
(3)(1)
(2)
- 43 -
OIL AND OIL FILTER CHANGE
ENGINE OIL AND OIL FILTER CHANGE
See section Preventive maintenance schedule.
TOPPING UP THE COMPRESSOR OIL
1. Stop the compressor. Wait a few minutes until the pressure is released through the automatic blow-down valve. Make sure that all pressure is released by loosening the filler plug (1) one turn.
2. Wait a few minutes until the oil level is constant.3. Remove the filler plug (1) and top up with oil until
the pointer of the oil level gauge (2) is in the upper part of the green area.
4. Reinstall and tighten the filler plug (1).
COMPRESSOR OIL AND OIL FILTER CHANGE
The quality and the temperature of the oil determinethe oil change interval.The prescribed interval is based on normal operatingconditions and an oil temperature of up to 100 °C(212 °F) (see section Preventive maintenanceschedule).
When operating in high ambient temperatures, in verydusty or high humidity conditions, it is recommendedto change the oil more frequently.
(2)(1)
The prescribed interval for compressoroil change shall not be exceeded in anycase. When the oil exchange interval isexceeded, this could lead to seriousdamage to the compressor.In case the compressor oil lifetime hasbeen exceeded please consult the AtlasCopco Customer Center for appropriatecleaning and flushing instructions.
In this case, contact Atlas Copco.
- 44 -
1. Remove cover (1).2. Run the compressor until warm.3. Close the outlet valve(s) (4) and stop the
compressor.4. Wait until the pressure is released through the
automatic blow-down valve.5. Unscrew the oil filler plug (3) one turn. This
uncovers a vent hole, which permits any pressure in the system to escape.
6. Drain the compressor oil by removing all relevant drain plugs (5-10). Catch the oil in a drain pan.
7. Screw out the filler plug (2) to speed up draining.8. After draining, place and tighten the drain plugs
(5-10).9. Remove the oil filters (2), e.g. by means of a
special tool. Catch the oil in a drain pan.10. Clean the filter seat on the manifold, taking care
that no dirt drops into the system.11. Oil the gasket of the new filter element. Screw it
into place until the gasket contacts its seat, then tighten one half turn only.
12. Fill the air receiver until the pointer of the oil level gauge is in the upper part of the green area. Be sure that no dirt gets into the system.
13. Reinstall and tighten the filler plug.14. Start the compressor and let it run unloaded for a
few minutes.15. Stop the compressor, wait a few minutes and top
up with oil until the pointer of the oil level gauge is in the upper part of the green area.
(1)
(6)
(7)
(10)
(9)
(8)
(2)
(3)
(4)
(5)
Never add more oil. Overfilling results inoil consumption.
- 45 -
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 *
- 46 -
COOLANT SPECIFICATIONS
The use of the correct coolant is important for goodheat transfer and protection of liquid-cooled engines.Coolants used in these engines must be mixtures ofgood quality water (distilled or de-ionised), specialcoolant additives and if necessary freeze protection.Coolant that is not to manufacturer's specification willresult in mechanical damage of the engine.The freezing point of the coolant must be lower thanthe freezing point that can occur in the area. Thedifference must be at least 5 °C (9 °F). If the coolantfreezes, it may crack the cylinder block, radiator orcoolant pump.Consult the engine's operation manual and follow themanufacturer's directions.
PARCOOL EG
PARCOOL EG is the only coolant that has beentested and approved by all engine manufacturerscurrently in use in Atlas Copco compressors andgenerators.Atlas Copco's PARCOOL EG extended life coolant isthe new range of organic coolants purpose designedto meet the needs of modern engines. PARCOOL EGcan help prevent leaks caused by corrosion.PARCOOL EG is also fully compatible with allsealants and gasket types developed to join differentmaterials used within an engine.PARCOOL EG is a ready to use Ethylene Glycolbased coolant, premixed in an optimum 50/50dilution ratio, for antifreeze protection guaranteed to-40°C (-40°F).
Because PARCOOL EG inhibits corrosion, depositformation is minimized. This effectively eliminatesthe problem of restricted flow through the enginecoolant ducts and the radiator, minimizing the risk forengine overheating and possible failure.It reduces water pump seal wear and has excellentstability when subjected to sustained high operatingtemperatures.PARCOOL EG is free of nitride and amines to protectyour health and the environment. Longer service lifereduces the amount of coolant produced and needingdisposal to minimise environmental impact.
Never remove the cooling system fillercap while coolant is hot.The system may be under pressure.Remove the cap slowly and only whencoolant is at ambient temperature. Asudden release of pressure from a heatedcooling system can result in personalinjury from the splash of hot coolant.
It is strongly recommended to use AtlasCopco branded coolant.
Never mix different coolants and mix thecoolant components outside the coolingsystem.
PARCOOL EG
To ensure protection against corrosion, cavitation and formation of deposits, the concentration of the additivesin the coolant must be kept between certain limits, as stated by the manufacturer's guidelines. Topping up thecoolant with water only, changes the concentration and is therefore not allowed.Liquid-cooled engines are factory-filled with this type of coolant mixture.
PARCOOL EG Concentrate
Liter US gal Order numbercan 5 1.3 1604 5308 00can 20 5.3 1604 5307 01barrel 210 55.2 1604 5306 00
Liter US gal Order numbercan 5 1.3 1604 8159 00
- 47 -
HANDLING PARCOOL EG
PARCOOL EG should be stored at ambienttemperatures, while periods of exposure totemperatures above 35 °C (95 °F) should beminimized. PARCOOL EG can be stored for aminimum of 5 years in unopened containers withoutany effect on the product quality of performance.PARCOOL EG is compatible with most othercoolants based on ethylene glycol, but you only getthe benefits of 5 years protection when its used on itsown. Exclusive use of PARCOOL EG isrecommended for optimum corrosion protection andsludge control.For simple density-measuring of Ethylene Glycol andPropylene Glycol in general the standard available‘density’ measuring devices are used to measure theconcentration of EG. In case a device is used tomeasure EG, no PG can be measured afterwards as aresult of the difference in the density. More specificmeasurements can be done by the use of arefractometer. This device can measure both EG andPG. A mix of both products will be show unreliableresults!Mixed EG coolants with identical glycol type can bemeasured by use of a refractometer as well as the‘density’ system. The mixed coolants will beconsidered as one product.The use of distilled water is recommended. If youhave exceptionally soft water it would be acceptable,as well. Basically, the engine metals are going tocorrode to some extent no matter what water you use,and hard water will encourage the resulting metalsalts to precipitate.PARCOOL EG comes as a pre-mixed coolant tosafeguard the quality of the complete product.It is recommended that topping up of the coolingsystem is always done with PARCOOL EG.
COOLANT CHECK
In order to guarantee the lifetime and quality of theproduct, thus to optimise engine protection, regularcoolant-condition-analysis is advisable.The quality of the product can be determined by threeparameters:
Visual check• Verify the outlook of the coolant regarding colour
and make sure that no loose particles are floating around.
pH measurement• Check the pH value of the coolant using a pH-
measuring device.• The pH-meter can be ordered from Atlas Copco
with part number 2913 0029 00.• Typical value for EG = 8.6.• If the pH-level is below 7 or above 9.5, the coolant
should be replaced.
Glycol concentration measurement• To optimise the unique engine protection features
of the PARCOOL EG the concentration of the Glycol in the water should be always above 33 vol.%.
• Mixtures with more than 68 vol.% mix ratio in water are not recommended, as this will lead to high engine operating temperatures.
• A refractometer can be ordered from Atlas Copco with part number 2913 0028 00.
TOPPING UP/REPLACING COOLANT
• Verify if the engine cooling system is in a good condition (no leaks, clean,...).
• Check the condition of the coolant.• If the condition of the coolant is outside the limits,
the complete coolant should be replaced (see section Replacing the coolant).
• Always top-up with PARCOOL EG Concentrate / PARCOOL EG.
• Topping up the coolant with water only, changes the concentration of additives and is therefore not allowed.
Never remove the cooling system fillercap while coolant is hot.The system may be under pressure.Remove the cap slowly and only whencoolant is at ambient temperature. Asudden release of pressure from a heatedcooling system can result in personalinjury from the splash of hot coolant.
In case of a mix of different coolantproducts this type of measurementmight provide incorrect values.
/or graph:
oncentrate
sion tank at low level, this quantity is to beaining from the cooling system.
er indication -20° C (33%)er indication -22° Cer indication -25° Cer indication -30° Cer indication -36° C
EG Concentrate
- 48 -
TOPPING UP WITHOUT DRAINING FROM THE COOLING SYSTEM
The quantity of PARCOOL EG Concentrate to be topped up can be estimated with the following formula and
Corrections concentrate in measured system towards 50% volume by using PARCOOL EG C
14
33
33 17 14 50 4,850- = =* /
40,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
5,5
6,0
5 6 7 8 9 10 11 12 13 14 15 16
1
2
3
4
5
Example:Total volume coolant =Measured concentration =
In case of expanfilled without dr
1. Refractomet2. Refractomet3. Refractomet4. Refractomet5. Refractomet
LiterVol %
Liter PARCOOL
Engine coolant capacity (liter)
Top-up volume PARCOOL EG Concentrate without drainage
Top
-up
volu
me
(lite
r)
PN: 1604 8159 00
g system, can be estimated with the following formula and/
oncentrate
sion tank at normal level, this quantity is to the cooling system.
er indication -20° C (33%)er indication -22° Cer indication -25° Cer indication -30° Cer indication -36° C
EG Concentrate
- 49 -
TOPPING UP AFTER LIMITED QUANTITY DRAINING FROM THE COOLING SYSTEM
The quantity of PARCOOL EG Concentrate to be topped up after draining a calculated volume from the coolinor graph:Corrections concentrate in measured system towards 50% volume by using PARCOOL EG C
80
33
33
33
17
67
80 67 2050-
100-
= =* /
=
Example:Total volume coolant =Measured concentration =
In case of expanbe drained from
1. Refractomet2. Refractomet3. Refractomet4. Refractomet5. Refractomet
LiterVol %
Liter PARCOOL
PN: 1604 8159 00
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 840,0
2,5
5,0
7,5
10,0
12,5
15,0
17,5
20,0
22,5
25,0
1
2
3
4
5
Engine coolant capacity (liter)
Top-up volume PARCOOL EG Concentrate without drainage
Top
-up
volu
me
(lite
r)
- 50 -
REPLACING THE COOLANT
Drain• Completely drain the entire cooling system.• Used coolant must be disposed or recycled in
accordance with laws and local regulations.
Flush• Flush twice with clean water. Used coolant must
be disposed or recycled in accordance with laws and local regulations.
• From the Atlas Copco Instruction book, determine the amount of PARCOOL EG required and pour into the radiator top tank.
• It should be clearly understood that the risk for contamination is reduced in case of proper cleaning.
• In case a certain content of ‘other’ coolant remains in the system, the coolant with the lowest properties influences the quality of the ‘mixed’ coolant.
Fill• To assure proper operation and the release of
trapped air, run the engine until normal engine operation temperature is reached. Turn off the engine and allow to cool.
• Recheck coolant level and add if necessary.
CLEANING COOLERS
Keep the coolers clean to maintain the coolingefficiency.Service doors (1) are provided on both sides of the fancowl to allow easy access to the fan side surface of thecoolers.There are two cooler configurations, the push typeand the pull type.With the push type cooler the fuel cooler is at theinside.
The pull type cooler has the fuel cooler mountedoutside, in front of the cooler unit.Also the position of the fan blades differ.
Caution: do not top off when the engineis hot.
(1) (1)
- 51 -
Clean by air jet in the direction of the arrow. Steam cleaning in combination with a cleansing agentmay be applied (do not use jet at max. power).
Close the service door(s).
The aftercooler is cleaned similar to the coolercleaning described above.Before the aftercooler can be cleaned, the grid (1) andcover have to be removed.Now you are able to clean the aftercooler by air jetfrom the inside to the outside.
Remove any dirt from the coolers with afibre brush. Never use a wire brush ormetal objects.
To avoid damaging the coolers, anglebetween jet and coolers should beapprox. 90 °.
Protect the electrical and controllingequipment, air filters, etc. againstpenetration of moisture.Never leave spilled liquids such as fuel,oil, coolant and cleansing agents in oraround the compressor.
(1)
- 52 -
BATTERY CARE
If the battery is still dry, it must be activated asdescribed in section Activating a dry-chargedbattery.The battery must be in operation within 2 monthsfrom being activated; if not, it needs to be rechargedfirst.
ELECTROLYTE
Electrolyte in batteries is a sulphuric acid solution indistilled water.The solution must be made up before beingintroduced into the battery.
ACTIVATING A DRY-CHARGED BATTERY
• Take out the battery.• Battery and electrolyte must be at equal
temperature above 10 °C (50 °F).• Remove cover and/or plug from each cell.• Fill each cell with electrolyte until the level
reaches the mark on the battery. If there is no mark on the battery, the level must be above the plates for at least 10 mm (0.4 in) to 15 mm (0.6 in).
• Rock the battery a few times so that possible air bubbles can escape; wait 10 minutes and check the level in each cell once more; if required, add electrolyte.
• Refit plugs and/or cover.• Place the battery in the compressor.
RECHARGING A BATTERY
Before and after charging a battery, always check theelectrolyte level in each cell; if required, top up withdistilled water only. When charging batteries, eachcell must be open, i.e. plugs and/or cover removed.
Apply with preference the slow charging method andadjust the charge current according to the followingrule of thumb:Battery capacity in Ah divided by 20 gives safecharging current in Amp.
BATTERY MAINTENANCE
• Keep the battery clean and dry.• Keep the electrolyte level above the plates or at
the indicated level. Level above plates at least 10 mm (0.4 in) to 15 mm (0.6 in). Top up with distilled water only.
• Keep the terminals and clamps tight, clean, and lightely covered with petroleum jelly.
COMPRESSOR ELEMENT OVERHAUL
When a compressor element is due for overhaul, itneeds to be done by Atlas Copco. This guarantees theuse of genuine parts and correct tools with care andprecision.
Before handling batteries, read therelevant safety precautions and actaccordingly.
Read the safety instructions carefully.
Always pour the sulphuric acid carefullyinto the distilled water; never pour thewater into the acid. Use a commercial automatic battery
charger according to its manufacturer’sinstructions.
- 53 -
Servicing proceduresAIR FILTERS ENGINE / COMPRESSOR
MAIN PARTS
CLEANING THE DUST TRAP
To remove dust from the dust trap pinch the vacuatorvalve (6) several times.
The instructions apply to one air filter and should berepeated for both air filters engine and air filterscompressor.
1. Release the snap clips (1) and remove the dust trap cover (2). Clean the inside of the cover.
2. Withdraw the filter element (4) and safety cartridge (3) from the housing (5).Discard the filter element when damaged.A dirty safety cartridge (3) is an indication of a malfunctioning filter element.
3. Reassemble in reverse order of dismantling.4. Inspect and tighten all air intake connections.
1. Snap clips (4x) 4. Filter element2. Dust trap cover 5. Filter housing3. Safety cartridge 6. Vacuator valve
The Atlas Copco air filters are speciallydesigned for the application. The use ofnon-genuine air filters may lead tosevere damage of the engine and/orcompressor elements.
(6) (1)(2) (3) (4) (5)
REPLACING THE FILTER ELEMENT AND THE SAFETY CARTRIDGE
(1)(2)
(3)
(4)
(5)
Replace the filter element and the safetycartridge at the same time. New elementsshould be inspected for tears andpunctures before installation.
The safety cartridge cannot be cleaned.
- 54 -
AIR RECEIVER
The air receiver (1) is tested according to officialstandards. Regularly have inspections carried out inconformity with local regulations.
SAFETY VALVE
Following checks must be carried out:• A check of the opening of the lifting gear, twice a
year.• A check of the set pressure once a year according
to the local regulations. This check cannot be done on the compressor and must be carried out on a proper test bench.
FUEL SYSTEM
PRIMING INSTRUCTIONS
Prime the fuel system in order to fill the fuel filter.Prime the fuel system in order to purge trapped air(see paragraph Specific start procedure). The fuelsystem should be primed under the followingconditions:• Compressor is put in operation for the first time• Running out of fuel• Storage• Replacement of the fuel filter
Daily drain condensate.
(1)
(2)
All adjustments or repairs are to be doneby an authorized representative of thesafety valve (2) supplier, see sectionSpecific safety precautions. Fuel leaked or spilled onto hot surfaces
or electrical components can cause a fire.To help prevent possible injury, turn the“ON/OFF” switch in position “OFF”when changing fuel filters or waterseparator elements. Clean up fuel spillsimmediately.
Do not loosen the fuel lines at the fuelmanifold. The fittings may be damagedand/or a loss of priming pressure mayoccur when the fuel lines are loosened.
kd.fer
en
Functional test:Operate the system at maximum operating pressureand check for possible malfunctions and freedomfrom leaks. Personnel must avoid potential hazardousareas while testing and using the system.Replacement intervals:Specific replacement intervals must be consideredbased on previous service life, government orindustry recommendations, or when failures couldresult in unacceptable downtime, damage or injuryrisk.Put on safety caps when no hoses connected.
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REPLACING FILTER ELEMENTS
Refer to Caterpillar engine manual
MAINTENANCE QUICK ACTION FUEL COUPLINGS
Even with proper selection and installation, quicaction coupling life may be significantly reducewithout a continuing maintenance programFrequency should be determined by the severity othe application and risk potential. A maintenancprogram must be established and followed by the useand must include the following as a minimum:Visual inspection of quick action couplings:Any of the following conditions require immediatshut down and replacement of the quick actiocoupling:• Cracked, damaged, or corroded quick action
coupling parts.• Leaks at the fitting, valve or mating seal.• Broken coupling mounting hardware, especially
breakaway clamps.Visual inspection all other:• Leaking seals or port connections.• Excess dirt build-up on the coupling locking
means or on the interface area of either couplinghalf.
• Defective clamps, guards, and shields.• Fuel level system and any entrapment.
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Problem solvingIt is assumed that the engine is in good condition andthat there is adequate fuel flow to the filter andinjection equipment.
Make sure that the wires are not damaged and thatthey are clamped tight to their terminals.For denomination of switches, relays, etc., seeElectric system.See also section Operations overview.
Problem: Compressor capacity or pressure below normal.
An electrical fault must be traced by anelectrician.
Possible faults Corrective actions
Air consumption exceeds capacity of compressor. Check equipment connected.
Choked air filter elements (AF). Remove and inspect elements. Clean or replace, if necessary.
Regulating valve (RV) defective. Have regulating valve removed and inspected by an Atlas Copco Service representative.
Blow down valve stuck in open position. Check and correct as necessary.
Loading valve (LV) leaking past O-ring. With compressor running at max. load speed, disconnect hose leading to unloader. If air leaks from the hose, remove and inspect loading valve. Replace damaged or worn O-rings.
Oil separator element clogged. Have element removed and inspected by an Atlas Copco Service representative.
Air intake throttle valve remains partially closed. Remove air filters, air intake manifold and throttle valve spring seat. Withdraw the valve and inspect. Replace parts where necessary. Caution: the spring seat is fixed with 4 short and 2 long setscrews: first remove the short screws, then release the spring tension unscrewing the long ones.
Safety valve (SV) leaking. Remove and inspect. Replace if not airtight after reinstallation.
Blow-off valve leaking. Remove and inspect. Replace if necessary.
inspected by an Atlas Copco Service representative.
leaks; replace leaking hoses.
ld and throttle valve spring seat. Withdraw the valve and ry. Caution: the spring seat is fixed with 4 short and 2 long ews, then release the spring tension unscrewing the long
ual.
overheating”.
essary. Replace air filter elements and safety cartridges. cessary. Run the compressor for a few minutes, stop and
essary. Replace air filter elements and safety cartridges. cessary. Run the compressor for a few minutes, stop and
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Problem: Pressure in air receiver rises above maximum and causes safety valve to blow.
Problem: After working some time, the unit stops through a shutdown switch.
Problem: Air and oil mist expelles from air filters immediately after stopping.
Possible faults Corrective actions
Regulating valve (RV) opens too late or its ball valve spring is broken. Have regulating valve removed and
Air leaks in regulating system. Check hoses and their fittings. Stop
Air intake throttle valve does not close for some reason. Remove air filters, air intake manifoinspect. Replace parts where necessasetscrews: first remove the short scrones.
Minimum pressure valve malfunctioning. Remove and inspect valve.
Blow-off valve malfunctioning. Remove and inspect valve.
Possible faults Corrective actions
Engine oil pressure too low. Refer to the engine instruction man
Compressor or engine overheating. See corrective actions “Compressor
Fuel tank contains insufficient fuel. Fill fuel tank.
Low coolant level. Top up cooling system.
Possible faults Corrective actions
Check valve at element outlet. Remove and inspect. Replace if necCheck the oil level and add oil if nerecheck oil level.
Plunger of oil stop valve jammed. Remove and inspect. Replace if necCheck the oil level and add oil if nerecheck oil level.
; when banked with other compressors, leave space
leaning coolers.
mended oil if necessary.
opening and closing. Replace if out of order.
d by an Atlas Copco Service representative.
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Problem: Compressor overheating.
Alternator precautions1. Never reverse the polarity of the battery or the
alternator.2. Never break any alternator or battery connections
while the engine is running.3. When recharging the battery, disconnect it from
the alternator. Before using booster cables to start the engine, be sure of the polarity and connect the batteries correctly.
4. Never operate the engine without the main or voltage sensing cables connected in the circuit.
Possible faults Corrective actions
Insufficient compressor cooling. Locate compressor away from wallsbetween them.
Oil cooler clogged externally. Clean oil cooler. Refer to section C
Oil cooler clogged internally. Consult Atlas Copco.
Oil filters clogged. Replace oil filters.
Oil level too low. Check oil level. Top up with recom
Thermostatic by-pass valve remains stuck in opened position. Remove valve and check for proper
Fan blade(s) broken. Check and correct if necessary.
Oil stop valve malfunctioning. Remove and inspect valve.
Oil separator element (OS) clogged. Have element removed and inspecte
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OILTRONIX FAILURE
Manually locking the valve (temporarysolution)Disconnect the connector (1) of the stepper motor, toensure that the stepper motor does not try to rotate thevalve.Rotate the white coupling of the valve manually untilthe blind hole in the coupling (3) is in line with thethreaded hole (2) in the housing.
Block the valve by screwing a bolt (M5 x 20) throughthe housing and in the blind hole in the coupling.
Check the correct position of the blindhole with a ∅ 4 mm pin.
Let an Atlas Copco technician repair orreplace defective parts asap.
(1)
(2)
(3)
eesst
INLET SHUTDOWN VALVE
The inlet shut down valve is a safety devicepreventing the engine from over speeding whensucking in combustible fumes. When the engine max.RPM is exceeded a pneumatically controlled solenoidvalve closes off the air inlet and the fuel supply to theengine is cut.
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Available optionsADDITIONAL FUELFILTER
In dusty environments or in situations where the fuelquality is not up to the normal standard, thisadditional fuel filter gives an extra protection to thefuel/combustion system.
SPARK ARRESTOR
The certified spark arrestor is an addition to thexhaust that makes it possible to operate thcompressor in hazardous environments like refineriewhere there is a possibility that inflammable fumecan be released. The spark arrestor prevents any ho(burning) particles from getting into the open air.It is integrated in the muffler.
gg
PRESSURE REGULATOR
A pressure regulating system according to Europeanor US standards for reducing the operating pressure.It will limit the operating pressure to 7 bar and allowthe operation of hand held pneumatic tools.
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COSMOSREMOTE MONITORING SYSTEM
COSMOS allows technicians to arrive at the rightlocation, at the right time, with the right informationand service materials so enabling you to give bettercustomer service, more up-time, and more accurateinvoicing than previously possible.
COSMOS provides information on:• time to maintenance• operational history (running hours, fuel levels,
events)• utilization data visualized in usage graphs• the location of the machine• all measured values and parameters
REGULATING SYSTEM DUAL PRESSURE
This option combines the dual pressure regulatinsystem with the fuel optimising system, thus savinon fuel costs.
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AFTER-COOLER WS+DD+PD
An integral after-cooler, with water separator (WS), isavailable to reduce the outlet air temperature toambient plus 10°C (18°F) and cut water content to amere 15%. The installation includes a by-pass over deafter-cooler.For applications that demand quality air, a finefiltration unit (DD) can be specified with the after-cooler package.For purer, but not breathing, air, a filtration unit (PD)can be specified with the after-cooler package.
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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 (6.64)M8 23 (16.97)M10 46 (34.69)M12 80 (59.04)M14 125 (92.25)M16 205 (151.29)
Thread size Torque value (Nm / lbf.ft) M6 15 (11.07)M8 39 (28.78)M10 78 (57.56)M12 135 (99.63)M14 210 (154.98)M16 345 (254.61)
Assemblies Torque value (Nm / lbf.ft)Compressor to frame:Bolts, elements/gear casing 46 (33.95)Bolts, elements/support 80 (59.04)Bolts, support/buffer 205 (151.29)Bolts, buffer/frame 80 (59.04)Engine to frame:Bolts, engine/support 205 (151.29)Bolts, support/buffer 46 (33.95)Bolts, buffer/frame 23 (16.97)Lifting beams to frame:Bolts, lifting beams/yoke (M12) 125 (92.25)Bolts, lifting beams/yoke (M16) 205 (151.29)Bolts, lifting beams/A-Frames 205 (151.29)Bolts, A-Frames/frame 205 (151.29)Hose clamps:Pebra hose clamps on all IC/radiator hoses
12 (8.85)
Secure the drain cock and tank cap of the fuel tank handtight.
1400 CD7 XRVO 727 Cd - XRVO 1550 CD71
14.50206825363
1400 CD7 XRVO 727 Cd - XRVS 1550 CD716232273925513150122-1014--
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COMPRESSOR / ENGINE SPECIFICATIONS
REFERENCE CONDITIONS
The inlet conditions are specified at the air inlet grating outside the canopy.
LIMITATIONS
Designation XRXO 667 Cd - XRXO Absolute inlet pressure bar(e) 1
psi 14.5Relative air humidity % 0Air inlet temperature °C 20
°F 68Nominal effective working pressure bar(e) 30
psi 435
Designation XRXO 667 Cd - XRXO Minimum effective receiver pressure bar(e) 19
psi 275Maximum effective receiver pressure, compressor unloaded bar(e) 32
psi 464Maximum ambient temperature at sea level
without aftercooler °C 55°F 131
with aftercooler °C 50°F 122
Minimum starting temperature °C -10°F 14
Minimum starting temperature, with coldstart equipment °C -°F -
Altitude capability see separate curve on page 67
1400 CD7 XRVO 727 Cd - XRVO 1550 CD7ull fan Push fan Pull fan
18001300
665 720 7121409 1525 1509658 - 7041394 - 1492
109.3240.079.6
174.264.3
141.153.8116.838.983.0
46.3 42.0 42.42.09 2.62 2.6546.8 - 42.92.92 - 2.68
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PERFORMANCE DATA
At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated.
Designation XRXO 667 Cd - XRXO Push fan P
Engine shaft speed, normal and maximum r/min 1800Engine shaft speed, compressor unloaded r/min 1300Free air delivery 1) without aftercooler l/s 672
cfm 1424with aftercooler l/s -
cfm -Fuel consumption- at 100% FAD Fuel expert kg/h 110.9
lb/h 244.5- at 75% FAD Fuel expert kg/h 80.8
lb/h 178.1- at 50% FAD Fuel expert kg/h 65.3
lb/h 144.0- at 25% FAD Fuel expert kg/h 54.6
lb/h 120.4- at unload Fuel expert kg/h 39.5
lb/h 87.1Specific fuel consumption without aftercooler g/m3 45.8
lb/1000 cu.ft 2.86with aftercooler g/m3 -
lb/1000 cu.ft -
30.0032739.63901943086
-
94.4
122.4
0 cfm)
1400 CD7 XRVO 727 Cd - XRVO 1550 CD7ull fan Push fan Pull fan
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1) Free air delivery is measured according to ISO 1217 ed.3 1996 annex D
Typical oil content of compressed air mg/m3 free air 3oz/1000 cu.ft 0.003
Engine oil consumption (maximum) g/h 277.3oz/h 9.78
Compressed air temperature at outlet valve
without aftercooler °C 90°F 194
with aftercooler °C 30°F 86
Noise level- Sound pressure level (LP), complies with ISO 2151 under free field conditions at 7 m distance
dB(A) -
- Sound pressure level (LP), complies with EPA under free field conditions at 7 m distance
dB(A) 94.4
- Sound power level (LW) complies with 2000/14/EC dB(A) 122.4
Tolerance: • +/- 5% 25 l/s (53 cfm) < FAD < 250 l/s (53• +/- 4% 250 l/s (530 cfm) < FAD
The international standard ISO 1217 corresponds tofollowing national standards:
• British BSI 1571 part 1• German DIN 1945 Part 1• Swedish SS-ISO 1217• American ANSI PTC9
Designation XRXO 667 Cd - XRXO Push fan P
0
3 281
6 562
9 843
13.124
10 20 30 40 50 60
50 68 86 104 122 140
1550 CD7
Temperature °C
Alti
tude
ft
Temperature °F
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ALTITUDE UNIT PERFORMANCE CURVE
Max. allowable working pressure as a function altitude and ambient temperature.
0
3 281
6 562
9 843
13.124
0
1000
2000
3000
4000
-10 0 10 20 30 40 50 60
14 32 50 68 86 104 122 140
XRXO 667 Cd - XRXO 1400 CD7
Temperature °C
Alti
tude
m
Alti
tude
ft
0
1000
2000
3000
4000
-10 0
14 32
XRVO 727 Cd - XRVO
Alti
tude
m
Temperature °F
All units
l 60US gal 15.85l 58US gal 15.32
stem l 72US gal 19.02
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DESIGN DATA
Compressor
Engine
1) With filter change.
DesignationNumber of compression stages 2
Designation All unitsMake CaterpillarType C18 TTCoolant LiquidNumber of cylinders 6Bore mm 145
in 5.71Stroke mm 183
in 7.2Swept volume l 18.1
cu.in 1104.5Output acc. to DIN 6271 at normal shaft speed
kW 522BHP 700
- Load factor % C - rated engine, refer to CAT engine manual
DesignationCapacity of oil sump:- Initial fill
- Refill (max.) 1)
Capacity of cooling sy
and dimensions
Dry Weight
Wet Weight
Dimensions L x W x H
5100 5310 4000 x 2200 x 22785210 5420
4000 x 2200 x 20515460 5670
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Unit
1) Air required for engine and compressor element cooling, for combustion and forcompression.
Compressor weight
Designation All unitsCapacity of compressor oil system l 80
US gal 21.13Net capacity of air receiver l 143
US gal 37.78Air volume at inlet grating (approx.) 1)
m3/s 23cu.ft/s 812
Designation
Push fanPull fanPull fan with AC
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Dataplate1 Company code2 Product code3 Unit serial number4 Name of the manufacturer5 EEC or national type approval number6 Unit identification number7 Total weight8 Model9 Working pressure10 Speed11 Engine power12 Manufacturing year
(1) (2) (3)
(4)(5)(6)
(7)
(8)(9)
(10)(11)
(12)
400 CD7 XRVO 727 Cd - XRVO 1550 CD730435130266
Cold start equipment35
508130266-25-1314337.7
- 71 -
LegislationPARTS, SUBJECTED TO PRESSURE EQUIPMENT DIRECTIVE 97/23/EC, CAT. II AND ABOVE
Safety valve: cat. IV
Air Oil separator
Designation XRXO 667 Cd - XRXO 1Set pressure bar(e) 35
psi 508Design temperature °C 130
°F 266
Designation StandardDesign pressure bar(e) 35
psi 508Design temperature max. °C 130
°F 266Design temperature min. °C -25
°F -13Volume l 143
US gal 37.7
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PARTS, SUBJECTED TO CAT. I AND COVERED BY THE MACHINE DIRECTIVE 89/392/EC
All other parts
PARTS, SUBJECTED TO ART. I, PARAGRAPH 3.3
All other parts
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DisposalGENERAL
When developing products and services, Atlas Copcotries to understand, address, and minimize thenegative environmental effects that the products andservices may have, when being manufactured,distributed, and used, as well as at their disposal.Recycling and disposal policy are part of thedevelopment of all Atlas Copco products. AtlasCopco company standards determine strictrequirements.Selecting materials the substantial recyclability, thedisassembly possibilities and the separability ofmaterials and assemblies are considered as well as theenvironmental perils and dangers to health during therecycling and disposal of the unavoidable rates of notrecyclable materials.Your Atlas Copco compressor consists for the mostpart of metallic materials, that can be remelted insteelworks and smelting works and that is thereforealmost infinite recyclable. The plastic used islabelled; sorting and fractioning of the materials forrecycling in the future is forseen.
DISPOSAL OF MATERIALS
Dispose contaminated substances and materialseparately, according to local applicableenvironmental legislations.Before dismantling a machine at the end of itsoperating lifetime drain all fluids and dispose ofaccording the applicable local disposal regulations. Remove the batteries. Do not throw batteries into thefire (explosion risk) or into the residual waste.Separate the machine into metal, electronics, wiring,hoses, insulation and plastic parts. Dispose all components according to the applicabledisposal regulations.Remove spilled fluid mechanically; pick up the restwith absorbing agent (for example sand, sawdust) anddispose it according the applicable local disposalregulations. Do not drain into the sewage system orsurface water.
This concept can only succeed with yourhelp. Support us by disposingprofessionally. By assuring a correctdisposal of the product you help toprevent possible negative consequencesfor environment and health, that canoccur with an inappropriate wastehandling.Recycling and re-usage of material helpsto preserve natural resources.
.........................................................
........................................................
By initials
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Maintenance Log
Compressor .......................................................................................... Customer ......................................
Serial number........................................................................................ ........................................................
Service hours Maintenance action Date
3)
in
f
to
d.
tt’nt x
x
e
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Following documents are provided with this unit:
– Test Certificate– EC Declaration of Conformity:
Atlas Copco Airpower n.v. puorG ocpoC saltA eht nihtiw ynapmoc A Postal address Visitors address Phone: +32 (0)3 870 21 11 Com. Reg. Antwerp 44651P.O. Box 100 Boomsesteenweg 957 Fax: +32 (0)3 870 24 43 V.A.T. 403.992.231 B-2610 Wilrijk-Antwerp B-2610 Wilrijk-Antwerp
evitatneserper ocpoC saltA lacol ruoy tcatnoc esaelp ,ofni roF muigleB muigleBwww.atlascopco.com
p.1(
Form
5009
060
0 02
ed
. 07,
201
0-03
-15
1 DECLARATION OF INCORPORATION2 We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product 3 Machine name : Compressor4 Commercial name :5 Serial number :
6
7
must not be put into service until the machine in which it is intended to be incorporated into or assembled with, isconformity with the relevant Essential Health and Safety Requirements of the EC-Directive 2006/42/EC and its amendments on the approximation of the laws of the Member States relating to Machinery.
EC DECLARATION OF CONFORMITY
8 We, Atlas Copco Airpower n.v., hereby declare that the product which falls under the provisions of article 12.2 othe EC Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery, as a component/quasi machine is in conformity with the relevant Essential Health and Safety Requirements of this directive.We, Atlas Copco Airpower N.V., undertakes, in response to a reasoned request by the national authorities,transmit the relevant information on the partly completed machinery. The information on the relevant partscan be obtained prejudice to the intellectual property rights of Atlas Copco Airpower N.V
The machinery complies also with the requirements of the following directives and their amendments as indicate
Directive on the approximation of laws of the Member States relating to
Harmonized and/or Technical Standards used
Am
a. Pressure equipment 97/23/EC
b. CE24/6002 ytefas yrenihcaMEN ISO 12100-1 EN ISO 12100-2
EN 1012-1 c. Simple pressure vessel 87/404/EEC
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
9
10
11.a The harmonized and the technical standards used are identified in the attachments hereafter 11.b Atlas Copco Airpower n.v. is authorized to compile the technical file
12 Conformity of the specification to the directives
Conformity of the product to the specification and by implication to th
directives13 Issued by Product engineering Manufacturing14 Name15 Signature
16 Place , Date
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