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 N2954 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 of unauthorized parts is noLiability.The manufacturer does not accept any liability for any damage arisingconversions made without the manufacturer's approval in writing.Neglecting maintenance or making changes to the setup of the machine canfire risk.While every effort has been made to ensure that the information in this manassume responsibility for possible errors.

Copyright 2010, Atlas Copco Airpower n.v., Antwerp, Belgium.Any unauthorized use or copying of the contents or any part thereof is prohThis applies in particular to trademarks, model denominations, part number- 4 -

t covered by Warranty or Product

from modifications, additions or

result in major hazards, including

ual is correct, Atlas Copco does not

ibited.s and drawings.

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

Table of contents1 Safety precautions ...................................... 71.1 Introduction .................................................. 71.2 General safety precautions ........................... 81.3 Safety during transport and installation ....... 91.4 Safety during use and operation................... 91.5 Safety during maintenance and repair........ 111.6 Tool applications safety ............................. 121.7 Specific safety precautions......................... 13

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

............................................. 36

............................................. 36

............................................. 36

............................................. 36

............................................. 36utions.................................. 36

intenance schedule .............. 37chedule compressor............. 37ns........................................ 40 oil....................................... 40............................................. 41........................................... 42e oil level ........................... 42ressor oil level.................... 42

er change ............................. 43nd oil filter change.............. 43 the compressor oil .............. 43 oil and oil filter change...... 43il Flushing Procedure .......... 45ications ................................ 46 EG ...................................... 46- 5 -

2 Leading particulars .................................. 142.1 General description .................................... 14

3 Main parts - Open Frame ........................ 163.1 Regulating system ...................................... 183.1.1 Overview................................................ 183.1.2 Air flow.................................................. 193.1.3 Oil system .............................................. 193.1.4 Pneumatic regulating system ................. 203.2 Electric system ........................................... 223.3 Markings and information labels ............... 24

4 Operating instructions ............................. 254.1 Transport and installation instructions ....... 254.1.1 Lifting instructions................................. 254.2 Night lights................................................. 264.3 Before starting ............................................ 264.4 Starting / Stopping...................................... 284.4.1 Operations overview .............................. 284.4.2 Battery switch ........................................ 284.4.3 Control panel.......................................... 294.4.4 Specific start procedure.......................... 29

5 Maintenance5.1 Liability.........5.2 Service paks ..5.3 Service kits....5.3.1 Storage ......5.3.2 Safety preca5.4 Preventive ma5.5 Maintenance s5.6 Oil specificatio5.6.1 Compressor5.6.2 Engine oil..5.7 Oil level check5.7.1 Check engin5.7.2 Check comp5.8 Oil and oil filt5.8.1 Engine oil a5.8.2 Topping up5.8.3 Compressor5.9 Compressor O5.10 Coolant specif5.10.1 PARCOOL

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 a5.14.4 Battery maint5.15 Compressor elem

6 Servicing proce6.1 Air filters engin6.1.1 Main parts ...6.1.2 Cleaning the 6.1.3 Replacing the

the safety car6.1.4 Air receiver..6.1.5 Safety valve.6.2 Fuel system......6.2.1 Priming instru6.2.2 Replacing filt6.2.3 Maintenance

fuel coupling

7 Problem solvin7.1 Oiltronix failure

8 Available options ...................................... 60

9 Technical specifications ........................... 639.1 Torque values ............................................. 639.1.1 General torque values ............................ 639.1.2 Critical torque values ............................. 639.2 Compressor / engine specifications............ 649.2.1 Reference conditions.............................. 649.2.2 Limitations ............................................. 649.2.3 Performance data ................................... 659.2.4 Altitude unit performance curve ............ 679.2.5 Design data............................................. 68- 6 -

battery .............................. 52enance............................... 52

ent overhaul .................... 52

dures ................................ 53e / compressor ................... 53........................................... 53dust trap ............................ 53 filter element and tridge ................................. 53........................................... 54........................................... 54........................................... 54ctions ............................... 54

er elements........................ 55Quick action s ......................................... 55

g ........................................ 56.......................................... 59

10 Dataplate ................................................... 70

11 Legislation ................................................. 7111.1 Parts, subjected to Pressure Equipment

Directive 97/23/EC, cat. II and above........ 7111.2 Parts, subjected to cat. I and covered

by the Machine Directive 89/392/EC......... 7211.3 Parts, subjected to art. I, paragraph 3.3 ...... 72

12 Disposal ..................................................... 7312.1 General ....................................................... 7312.2 Disposal of materials.................................. 73

13 Maintenance Log ...................................... 74

- 7 -

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.

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

GENERAL SAFETY PRECAUTIONS

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

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

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 maintenance

s and information labels on the

safety labels are damaged ormust be replaced to ensure

area neet. Lack of order willf accidents. the unit, wear safety clothing.e kind of activities these are:ear protection, safety helmet), safety gloves, protectiveoes. Do not wear the hair longt long hair with a hairnet), org or jewelry.

against fire. Handle fuel, oil and care because they arestances. Do not smoke orked flame when handling suchp a fire-extinguisher in the- 8 -

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

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

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

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

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

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

schedule.12 Mind the marking

unit.13 In the event the

destroyed, they operator safety.

14 Keep the work increase the risk o

15 When working onDepending on thsafety glasses, (including visorclothing, safety shand loose (protecwear loose clothin

16 Take precautions anti-freeze withinflammable subapproach with nasubstances. Keevicinity.

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 theOFF 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, Helicopter lifting is notIt is strictly forbidden tounder a lifted load. Nevresidential areas. Liftinshall be kept within saf1 Before towing the u

- ascertain that thdepressurized,

- check the tow btowing eye. Alstowing vehicle,

- check the towintowing vehicle,

- check that the toleg is safely lock

- ascertain that theon the hook,

- check that the wtyres are in gcorrectly,

- connect the signand connect the

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

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

- check wether springs on wheelchocks aremissing or broken.

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

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

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 in

riven machine cooling fan, thisating of the unit; if taken in forngine power will be reduced.e compressor, switch it off.ht on the ABS module or in theplease contact Atlas Copco.

SE AND OPERATION

s to operate in a fire-hazardoush engine exhaust has to bepark arrestor to trap incendiary

ins carbon monoxide which is a the unit is used in a confinede engine exhaust to the outsidepipe of sufficient diameter; doy that no extra back pressure isngine. If necessary, install ane any existing local regulations.e unit has sufficient air intakeecessary, install extra air intake- 9 -

chains or ropes. allowed. dwell or stay in the risk zoneer lift the unit over people or

g acceleration and retardatione limits.nit:e pressure vessel(s) is (are)

ar, the brake system and theo check the coupling of the

g and brake capability of the

w bar, jockey wheel or standed in the raised position, towing eye can swivel freely

heels are secure and that theood condition and inflated

alisation cable, check all lightspneumatic brake couplers,

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

5 Place the unit on level ground and apply theparking brake before disconnecting the unit fromthe towing vehicle. Unclip the safety break-awaycable or safety chain. If the unit has no parkingbrake or jockey wheel, immobilize the unit byplacing chocks in front of and/or behind thewheels. When the tow bar can be positionedvertically, the locking device must be applied andkept in good order. The unit must always be used/parked/stored in a non publicly accessible area,locked away from access by unauthorizedpersons.

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

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

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

by the engine or dmay cause overhecombustion, the e

12 Before moving th13 If the warning lig

vehicle lights up,

SAFETY DURING U

1 When the unit haenvironment, eacprovided with a ssparks.

2 The exhaust contalethal gas. Whenspace, conduct thatmosphere by a this in such a wacreated for the eextractor. ObservMake sure that thfor operation. If nducts.

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 safeguardenext to the valve.

6 No external force mvalves, e.g. by pulauxiliary equipmenwater separator, a lthe air outlet valves

7 Never move a unitare connected to damage to valves, m

8 Do not use compcompressor, withoubreathing purposesdeath. For breathinair must be adequatlegislation and staalways be supplied

9 Distribution pipewcorrect diameter apressure. Never deteriorated hoses.before the lifetime type and size of hos

10 If the compressor is to be used for sand-blastingor will be connected to a common compressed-airsystem, fit an appropriate non-return valve (checkvalve) between compressor outlet and theconnected sand-blasting or compressed-airsystem. Observe the right mounting position/direction.

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

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

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,

A): room to be classified as as area and an obvious warning permanently at each entrance

e entering the room, for event times, about the need to wear

(A): the warning(s) at theall be completed with the

on that also occasional visitorsprotectors,(A): special ear protectors thatfor this noise level and theosition of the noise shall bea special warning to that effect at each entrance.ts, which may be accidentallynnel, of which the temperature 80 C (176 F). The insulationrotecting these parts shall not behe parts have cooled down to.e unit in surroundings wherelity of taking in flammable or- 10 -

d with a safety cable, attached

ay be exerted on the air outletling on hoses or by installingt directly to a valve, e.g. aubricator, etc. Do not step on. when external lines or hosesthe outlet valves, to avoidanifold and hoses.

ressed air from any type oft taking extra measures, for

as this may result in injury org air quality, the compressedely purified according to localndards. Breathing air must

at stable, suitable pressure.ork and air hoses must be ofnd suitable for the workinguse frayed, damaged or

Replace hoses and flexiblesexpires. Use only the correcte end fittings and connections.

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

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

15 Periodically carry out maintenance worksaccording to the maintenance schedule.

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

- above 85 dB(noise-hazardoushall be placedto alert peoplrelatively shorear protectors,

- above 95 dBentrance(s) shrecommendatishall wear ear

- above 105 dBare adequate spectral compprovided and shall be placed

18 The unit has partouched by persocan be in exess ofor safety guard, premoved before troom temperature

19 Never operate ththere is a possibitoxic fumes.

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

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

23 Safety shoes showorkshop and if thefalling objects, weabe included.

24 If there is a risk fumes or dust, theprotected and dephazard, so must the

25 Remember that whfiner, invisible partpresent too; but theis not a reliableinvisible dust is not

26 Never operate thebelow or in excess technical specificat

SAFETY DURING MAINTENANCE AND REPAIR

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

repair work, and only tools which are in goodcondition.

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

3 All maintenance work, other than routine

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.

or perform any operationar the fuel or oil systems. Fuelt be completely purged, e.g. bybefore carrying out such

weld on, or in any way modify,Disconnect the alternator cablesg on the unit.bar and the axle(s) securely ifth the unit or when removing a

y on jacks.y of, or tamper with, the sound-. Keep the material free of dirts fuel, oil and cleansing agents.mping material is damaged,nt the sound pressure level from

ricating oils and greasesapproved by Atlas Copco or theacturer. Ascertain that thets comply with all applicables, especially with regard toe-risk and the possibility of generation of hazardous gases.tic with mineral oil.- 11 -

er apron and gloves, etc.uld be compulsory in anyre is a risk, however small, ofring of a safety helmet should

of inhaling hazardous gases, respiratory organs must beending on the nature of the eyes and skin.ere there is visible dust, theicles will almost certainly be fact that no dust can be seen indication that dangerous, present in the air. unit at pressures or speedsof its limits as indicated in theions.

attention, shall only be undertaken when the unitis stopped. Steps shall be taken to preventinadvertent starting. In addition, a warning signbearing a legend such as work in progress; donot start shall be attached to the startingequipment. On engine-driven units the batteryshall be disconnected and removed or theterminals covered by insulating caps. Onelectrically driven units the main switch shall belocked in open position and the fuses shall betaken out. A warning sign bearing a legend suchas work in progress; do not supply voltage shallbe attached to the fuse box or main switch.

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

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

11 Never weld oninvolving heat neand oil tanks mussteam-cleaning, operations. Neverpressure vessels. during arc weldin

12 Support the tow working underneawheel. Do not rel

13 Do not remove andamping materialand liquids such aIf any sound-dareplace it to preveincreasing.

14 Use only lubrecommended or machine manufselected lubricansafety regulationexplosion or firdecomposition orNever mix synthe

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 bshall be barred ovreciprocating machrotary ones to ensuinterference withinthe direction of rotstarting up the maalteration to the elegear, to check thafunction properly.

20 Maintenance and rein an operators Frequency and natuconditions.

21 When hot parts hafitting, special heatand, if required, oapplied.

22 When using cartequipment, ascertacartridge is used annot surpassed.

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

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

TOOL APPLICATIONS SAFETY

Apply the proper tool for each job. With theknowledge of correct tool use and knowing the- 12 -

een completed, the machineer at least one revolution forines, several revolutions forre that there is no mechanical the machine or driver. Checkation of electric motors whenchine initially and after anyctrical connection(s) or switcht the oil pump and the fan

pair work should be recordedlogbook for all machinery.re of repairs can reveal unsafe

ve to be handled, e.g. shrink-resistant gloves shall be usedther body protection shall be

ridge type breathing filterin that the correct type ofd that its useful service life is

limitations of tools, along with some common sense,many accidents can be prevented.Special service tools are available for specific jobsand should be used when recommended. The use ofthese tools will save time and prevent damage toparts.

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 aregas mixture forms through the vent explosive atmosphbattery if ventilatioand around the bathas been charged. - never smoke ne

recently been, ch- never break live

because a spark 4 When connecting

parallel to the unicables: connect theCB, then connect ththe unit. Disconnec

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

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

vessel:- the maximum working pressure ps in bar (psi),- the maximum working temperature Tmax in

C (F),

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 the

to a different pressure than that without the permission of the

ust be altered then use only by Seetru and in accordancevailable for the valve type. frequently tested and regularly

ld be periodically checked for

g device should be operated atan 75% of the set pressure to

ovement of internal parts. is influenced by factors such as operating environment and pressurised medium. should be replaced as part of there.e installed safety valve (see alsonce schedule).- 13 -

being charged, an explosivein the cells and might escapeholes in the plugs. Thus anere may form around then is poor, and can remain intery for several hours after itTherefore:ar batteries being, or havingarged, circuits at battery terminals,usually occurs.an auxiliary battery (AB) int battery (CB) with booster + pole of AB to the + pole ofe - pole of CB to the mass of

t in the reverse order.

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

- the capacity of the vessel V in l (US gal, Impgal, cu.ft).

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

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

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

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

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

7 Installation, design and connections should not bechanged.

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

safety valve be alteredstamped on the valveinstallation designer.If the set pressure mcorrect parts suppliedwith the instructions aSafety valves must bemaintained.The set pressure shouaccuracy.When fitted, the liftinpressures not less thensure free and easy mThe frequency of teststhe severity of theaggressiveness of theSoft seals and springsmaintenance proceduDo not paint or coat thPreventive maintena

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 dliquid-cooled diesel engThe engines power is element through a heav

CompressorThe compressor casingmounted on ball and rodriven by the engine, compressor delivers puInjected oil is usedlubricating purposes.

Compressor oil systemThe oil is boosted by air pressure. The system has nooil pump.The oil is removed from the air, in the air/oil vessel atfirst by centrifugal force, secondly through the oilseparator element.The vessel is provided with an oil level indicator.- 14 -

riven by a 6 cilinder in-lineine.

transmitted to the compressory-duty coupling.

houses two screw-type rotors,ller bearings. The male rotor,drives the female rotor. Thelsation-free air. for sealing, cooling and

RegulationThe compressor is provided with a single or dualpressure pneumatic regulating system and a blow-offvalve which is integrated in the unloader assembly.The valve is closed during operation by air receiverpressure and opens by air receiver pressure via thecompressor element when the compressor is stopped.When the air consumption increases, the air receiverpressure will decrease and vice versa.This receiver pressure variation is sensed by theregulating valve which, by means of control air to theunloader and an electronic engine speed regulator,matches the air output to the air consumption. The airreceiver pressure is maintained between the pre-selected working pressure and the correspondingunloading pressure.

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 apull fan.

Safety devicesA thermal shut-down sagainst overheating. Tha safety valve.The engine is equipped coolant temperature shuThe electric system isswitch.

Frame and axlesThe compressor/enginebuffers in a sturdy framThe frame is equippecollecting spilled fluidsunit is equipped with a lforklift openings. For florry fixing holes are eq

Serial number- 15 -

ensor protects the compressore air receiver is provided with

with low oil pressure and hight-down sensors.

equipped with a 24V main

unit is supported by rubbere.d with a bottom plate for. For transport at the site theifting beam (crane lifting) andixing the unit on site or on auipped at the corners.

The serial number (1) on top of the beam near the dataplate. It is also mentioned on the data plate (2) andinside the control box.

Control panelThe control panel grouping the air pressure gauge,control switch etc., is placed at the left hand/ rear endcorner.

Data plateThe compressor is furnished with a data plate (2)showing the product code, the unit serial number andthe working pressure (see chapter Dataplate).

(2) (1)

Main parts - Open Frame- 16 -

Reference NameA AlternatorAFce Air Filter (compressor element)AFe Air Filter (engine)AOV Air Outlet ValvesAR Air ReceiverB BatteryCEhp Compressor Element (High

PressureCElp Compre

PressureCP ControlDPar Drain PDSE DipstickE EngineEP ExhaustF FanFCc Filler CFCe Filler CFF Fuel FilFFp Fuel PreFPco Filler PlMPV MinimuOC Oil Coo

Reference NameOFce Oil Filter (compressor element)OFe Oil Filter (engine)OLG Oil Level GaugeR RadiatorRV Regulating ValveSL Scavenge LineSM Starting Motor- 17 -

)ssor Element (Low )

Panellug Air Receiver Engine Oil

Pipe

ap (coolant)ap (engine oil)ter Filterug (compressor oil)m Pressure Valveler

SOV Solenoid ValveSV Safety ValveUV Unloading Valve

REGULATING SYSTEM

OVERVIEW

(CBE)(CU)

(DP)(LV)(RV)

(MPV)(AOV)

(SL)(BVof)

(SV)(AR/OS)

(WPS)(TBV)

(OFce)(OT)

(OFe)

(SC)

(AFe)(AFce)

(AFS)

Reference NameAFce Air Filter (compr. element)AFe Air Filter (engine)AFS Air Filter SwitchAOV Air Outlet ValvesAR/OS Air Receiver / Oil SeparatorBOV Blow Off Valve

s Valve oil filteringle for Electrical devicesressor Element (high pressure)ressor Element (low pressure)l Unit

Pluge

ng Valveum Pressure Valveoler

lter (compressor element)lter (engine)op Valvenixre Sensor- 18 -

(OC)(F)(UA)(TV)(BOV)(E)

(CE lp)

(CE hp)

(OSV)(TS)

(PS)

(C)

BVof BypasC CouplCBE CubicCEhp CompCElp CompCU ControDP Drain E EnginF FanLV LoadiMPV MinimOC Oil CoOFce Oil FiOFe Oil FiOSV Oil StOT OiltroPS Pressu

AIR FLOW

Air drawn through the airfilter (AFce) into thecompressor element (CEhp CElp) is compressed. Atthe element outlet, compressed air and oil pass intothe air receiver/oil separator (AR/OS).A check valve prevents blow-back of compressed airwhen the compressor is stopped. In the air receiver/oilseparator (AR/OS), most of the oil is removed fromthe air/oil mixture.The oil collects in the receiver and on the bottom of

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 the

ass valve (TBV) starts openingure is 40C (104F).ent has an oil gallery in the

. The oil for rotor lubrication,s injected through holes in the

arings is ensured by oil injectedngs.xed with the compressed air,r element and re-enters the airs separated from the air asir flow. The oil that collects in

separator element is returned to scavenging line (SL), which isrestrictor. valve opens when the pressureis above normal because of aoil then by-passes the filter. For this reason, the oil filter

regular intervals (see sectionnce schedule).

Reference NameRV Regulating ValveSC Safety CartridgeSL Scavenge LineSV Safety ValveTBV Thermostatic Bypass ValveTS Temperature SensorTV ThrottleUA UnloadeWPS Working- 19 -

the separator element.The air leaves the receiver via a minimum pressurevalve (MPV) which prevents the receiver pressurefrom dropping below the minimum working pressure,even when the air outlet valves are open (specified insection Limitations). This ensures adequate oilinjection and prevents oil consumption. Theminimum pressure valve (MPV) also functions as acheck valve.The system comprises temperature sensors (TS),pressure sensors (PS) and a working pressure sensor(WPS).

compressor element.The thermostatic by-pwhen the oil temperatThe compressor elembottom of its casingcooling and sealing igallery.Lubrication of the beinto the bearing housiThe injected oil, mileaves the compressoreceiver, where it idescribed in section Athe bottom of the oil the system through aprovided with a flow The oil filter by-passdrop over the filter clogged filter. The without being filteredmust be replaced atPreventive maintena

Valver Assembly Pressure Sensor

PNEUMATIC REGULATING SYSTEM

(RV)

(AR/OS)- 20 -

(UA)(TV)(BOV)

(CE lp)

(CE hp)

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 meansassembly (UA), matchconsumption. The air rebetween the pre-selectcorresponding unloadinWhen starting the compis kept closed via receielement (CEhp CElp) tup in the receiver (ARclosed. The air output output (100%) to no ou1. Speed control of the

load speed and unloscrew compressor isspeed).

2. Air inlet throttling.If the air consumptionmaximum air output, maximum load speed afully open.

If the air consumption is less than the maximum airoutput, air receiver pressure increases and theregulating valve supplies control air to throttle valve(TV) to reduce the air output and holds air receiverpressure between the normal working pressure andthe corresponding unloading pressure. Unloadingpressure = normal working pressure + 1 bar (14.504psi).When the air consumption is resumed, the blow off- 21 -

of control air to the unloaderes the air output to the airceiver pressure is maintained

ed working pressure and theg pressure.ressor, the throttle valve (TV)ver pressure. The compressorakes in air and pressure builds). The throttle valve (TV) isis controlled from maximumtput (0%) by: engine between maximum ading speed (the output of a proportional to the rotating

is equal to or exceeds thethe engine speed is held atnd the throttle valve (TV) is

valve (BOV) closes and the throttle valve (TV)gradually opens the air intake and the electronic speedregulator increases the engine speed.The construction of the regulating valve (RV) is suchthat any increase (decrease) of the air receiverpressure above the pre-set valve opening pressureresults in a proportional increase (decrease) of thecontrol pressure to the throttle valve and theelectronic speed regulator.Part of the control air is vented to atmosphere, andany condensate discharged, through the vent holes.

ELECTRIC SYSTEM

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S110A

F2d10A

F2c10A

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3

3087

S48586 K4

10A

F2a

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)

5: 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

J1/P1-55

J1/P1-48

J1/P1-10

J1/P1-70

J1/P1-8

J1/P1-53

N2

J1/P1-42J1/P1-34J1/P1-50

J1/P1-52

S1

(9822 1016 16 - XRXO 667 / XRVO 727)- 22 -

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B1CAT Diagnostic

S3

2

4

1

3

sensorCombo

10A

F4

BNBNBU

BU S5S6

5533

51 50 42

57 2 1 3 551356

23

462612

473734

controllerOiltronix

1432

8765

d

r

i

v

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s

t

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p

p

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r

A+A-B+B-M3

YK5

N7 N6

COM4COM3COM2COM1NA1NA2NA3NA4 ALIM

GND

r

e

m

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c

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AB

GFCE DX1

S2C1

CAT ADEM A4J1/P1-61

J1/P1-9

J1/P1-69

J1/P1-65

J1/P1-63

ECM

K1

24VDC

W+G3 B+

B-D+

K0 M1

MK0

G2 -+

G1 -+

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 Horn

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 temperature

Inlet Shutdown Valve Dual pressure

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Y2

PT3SIGV+ 5VDCV+ 24VDC

UP

PT2SIGV-

V+ 5VDCV+ 24VDC

UP

H4

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

PT1SIGV-

V+ 5VDCV+ 24VDC

UP

TT1 - 23 -

K0 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

Y3 Solenoid valve,Y4 Solenoid valve,

Wire cross sections:a 1 mm2b 1.5 mm2f 10 mm2l 95 mm2

Wire colors:0 black1 brown2 red3 orange4 yellow5 green6 blue7 purple8 grey9 white

a6

1

9

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3

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1

9

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PT4SIGV-

V+ 5VDCV+ 24VDC

UP

TT4

1

9 8586

K1

LS1LS2

V-

H6P PS1

TT3

TT2

- 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.

Dont 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 OFFposition!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.

CONTROL PANEL SPECIFIC START PROCEDURE

edure when the compressor ise first time and after running oute fuel filter.ery switch.itch (1) up and hold it for fter releasing it, it will return to n.FF switch to position ON. nel will now perform a brief

on (I) and the starter motor will o start the engine.o start, switch the ON/OFFn and repeat steps 2, 3 and 4.

(1)(2)

(3) (4)(5)

(F1)(F2)

(O)

Reference Name1 Emerge2 Display3 Pressure4 Arrow U5 Arrow D6 Fuel levF1 F1 FuncF2 F2 Func0 Stop buI Start buON/OFF Power O

(1)- 29 -

Follow this start procput in operation for thof fuel or changing th Switch on the batt Push the toggle sw

about 5 seconds. Aits down positio

Switch the ON/OThe instrument paselftest.

Push the start buttautomatically try t

If the engine fails tswitch to OFF agai

(I)

(ON/OFF)

ncy stop (4 rows, 40 characters / row) gaugep buttonown button

el gaugetion buttontion buttonttonttonN/OFF switch

- 30 -

POWER ON / OFF

Switch on the battery switch.Switch the machine on by switching the ON/OFFswitch 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 (40C / 104F).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)

When the compressor is shut down because ofexceeding a parameter setting (e.g. compressortemperature) the display shows:

and than:

After the stopping procontinue.Restarting before the pimpossible because of tcranking procedure.

STOPPING

(O)

(ON/OFF)- 32 -

cedure has ended press F1 to

arameter is within its limits ishe parameter check before the

To turn off the compressor first press the button 0.The engine will run some time at min. speed to cooldown and will stop finally. The remaining time is shown in the display:

Meanwhile the air receiver is depressurised.Switch the ON/OFF switch to the position OFF.Wait until the display is dark.Switch the battery switch in the OFF position.

- 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 characters XXXX XXXX in the upper rightcorner stand for compressor type.

COMPRESSOR TYPE CONTROL MODE BATTERY VOLTAGE AMBIENT TEMPERATURE SOFTWARE VERSION COMPR. SERIAL N ENGINE SERIAL N FLEET NR (OptionThe F2 button return

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

The F1 button enters a menu, or confirms a newparameter setting.To select a menu, the button function text isF1:SELECT.To go back, the button function text is F2:BACK.

pressed, the topic next to ">" is

operator wishes to change theLANDS", he would press theNGUAGE" is next to ">".

ator has entered the language value is displayed under

EDERLANDS" and presses the

:- 34 -

R

R

al)

s to READY TO 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

If the F1 button is selected.For example, if the language to "NEDERF1 button when "LAFrom there the opermenu. The presentLANGUAGE.Then he scrolls to "NF1 button.The display will show

SERVICE TASK CONFIRMED

The following confirmseconds, or until the F

When the display showservice task that has bdisplayed (because it is

SERVICE IN ADVAN

When SERVICE IN user enters a submenu.If the next standard srunning hours, the user TASK.

Next to the next standard service task all activecustom service tasks are always displayed.When a service task is selected (pressing the buttonF1), this service task is triggered and confirmed.This confirmation is also displayed.

(option for XRXS only)stem has two regulating valvesI and a switch at the rear for (I) or higher (II) working

lve (RV) marked with I at awer than the regulating valve

eans the handle of RV I shouldan the handle of RV II. Thisvery important. When donewill not work correctly. working pressure of maximumrpm will increase to 1900 rpm) to deliver more FAD at this I can be set at a pressure higher but then there will be no speed

(F1)(F2)

(1)

(2)- 35 -

ation is displayed for 101 button is pressed.

s the Option status again theeen confirmed is no longer

confirmed).

CE

ADVANCE is selected the

ervice task is due within 50can choose NEXT SERVICE

When pressing the button F2, EXIT, the usergoes straight to READY TO START.

PRESSURE ADJUSTMENT

Single pressure systemThe working pressure is determined by the tension ofthe spring in the regulating valve (RV). This tensioncan be increased to raise the pressure and decreased tolower it by turning the adjusting wheel clockwise andanti-clockwise respectively.To adjust the normal working pressure, proceed asfollows:1. Loosen the lock nut of the regulating valve.2. Release Regulating Valve (turn out).3. With the outlet valves (AOV) closed, adjust the

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

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

Dual pressure systemThe dual pressure symarked with I and Iselecting the lowerpressure.Set the regulating vaworking pressure lomarked with II. This mbe scewed in less thpressure setting is otherwise the system When RV I is set at a25 bar (363 psi), the (instead of 1800 rpmlower pressure. RVthan 25 bar (363 psi),increase.

- 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 manufacturers 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 theOFF 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)

Maintenance schedule(continuation of page 37)

Initially at 50 h 250 h 1000 hDaily Every 6 months Yearly

Drain water from fuel filter xCheck electrolyte level and terminals of battery x x xCheck for leaks in air-, oil- or fuel system (2) x x xClean oil cooler x xClean radiator x xClean intercooler x xCheck alternator belt x xTest safety valve (10) xReplace bleed-off valv xClean oil stop valve xCheck rubber flexible xCheck shut down swit xReplace oil separator xAdjust fan V-belts (3) xReplace compressor o xReplace compressor o xAnalyse coolant (9) (5 xReplace air filter elem xReplace engine oil (3) xReplace engine oil filt xReplace primary fuel xReplace fuel prefilter x(to be continued on page- 38 -

e unloader

s (2)cheselement

x xil (1) (8)il filter (6) x)ent (1) (4) xer (3) xfilter (AC filter) (7) x(3) (7) x 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 -25C (-13F) and +30C (86F) PAROIL S PAROIL Extrabetween -10C (14F) and +30C (86F) PAROIL S PAROIL Ebetween -10C (14F) and +50C (122F) PAROIL Sxtreme PAROIL E

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 longeviPAROIL provides weconditions. Powerful chemical stability and reduce corrosion, evenextended periods.

PAROIL contains high quality anti-oxidants tocontrol deposits, sludge and contaminants that tend tobuild up under very high temperatures. PAROIL'sdetergent additives keep sludge forming particles in afine suspension instead of allowing them to clog yourfilter and accumulate in the valve/rocker cover area.PAROIL releases excess heat efficiently, whilstmaintaining excellent bore-polish protection to limitoil consumption.PAROIL has an excellent Total Base Number (TBN)retention and more alkalinity to control acid

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 -25C (-13F). 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 -15C(5F).

Synthetic engine oil P

Mineral engine oil PA

cancan

cancanbarrelcontainer- 41 -

ty.ar protection under extremeoxidation resistance, high

rust- inhibiting additives help within engines left idle for

formation.PAROIL prevents Soot build-upPAROIL is optimized for the latest low emissionEURO -3 & -2, EPA TIER II & III engines running onlow sulphur diesel for lower oil and fuel consumption.

AROIL Extra

ROIL E

Liter US gal Order number5 1.3 1604 6060 00

20 5.3 1604 6059 00

Liter US gal Order number5 1.3 1615 5953 00

20 5.3 1615 5954 00210 55.2 1615 5955 001000 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-40C (-40F).

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