Related Manuals for Atlas Copco XRYS 577
Summary of Contents for Atlas Copco XRYS 577
- Page 1 Instruction Manual for Portable Compressors English XRYS 577 Cd S3B APP - XRYS 1260 CD7 T4I APP Engine XRXS 607 Cd S3B APP - XRXS 1275 CD7 T4I APP CAT C18 XRVS 647 Cd S3B APP - XRVS 1350 CD7 T4I APP...
- Page 3 Instruction Manual for Portable Compressors XRYS 577 - XRYS 1260 XRXS 607 - XRXS 1275 XRVS 647 - XRVS 1350 Original instructions Printed matter N° 2954 6700 00 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com 11/2012...
- Page 4 Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors.
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Page 5: Table Of Contents
Table of contents Preface Undercarriage..........38 3.5.1 Wagon............ 38 Please read the following instructions carefully 3.5.2 Tandem EU ..........39 before starting to use your compressor. Safety precautions ........7 Markings and information labels ....43 Introduction ..........7 It is a solid, safe and reliable machine, built according to the latest technology. - Page 6 4.6.15 Fault codes ..........73 5.13.2 Topping up after limited quantity Available options ........112 4.6.16 Starting / Stopping via remote control ... 76 draining from the cooling system ..94 Technical specifications ......119 4.6.17 Emergency stop........76 5.13.3 Replacing the coolant......
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Page 7: Safety Precautions
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the compressor. INTRODUCTION The policy of Atlas Copco is to provide the users of It is the responsibility of management to appoint Take necessary steps to keep unauthorized persons... -
Page 8: General Safety Precautions
The manufacturer does not accept any liability for any GENERAL SAFETY PRECAUTIONS Care shall be taken to avoid damage to safety damage arising from the use of non-original parts and valves other pressure-relief devices, The owner is responsible for maintaining the unit for modifications, additions or conversions made especially to avoid plugging by paint, oil coke or in a safe operating condition. -
Page 9: Safety During Transport And Installation
Lifting acceleration and retardation cable or safety chain. If the unit has no parking shall be kept within safe limits. vehicle lights up, please contact Atlas Copco. brake or jockey wheel, immobilize the unit by placing chocks in front of and/or behind the... - Page 10 13 Never refill fuel while the unit is running, unless shall be placed permanently at each entrance The air line end connected to the outlet valve otherwise stated in the Atlas Copco Instruction to alert people entering the room, for even must be safeguarded with a safety cable, attached Book (AIB).
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Page 11: Safety During Maintenance And Repair
(check valves) to isolate recommended or approved by Atlas Copco or the present too; but the fact that no dust can be seen pressure systems. In addition, a warning sign machine manufacturer. -
Page 12: Tool Applications Safety
15 Protect the engine, alternator, air intake filter, 23 Make sure that oil, solvents and other substances electrical and regulating components, etc., to likely to pollute the environment are properly prevent moisture ingress, e.g. when steam- disposed of. cleaning. 24 Before clearing the unit for use after maintenance 16 When performing any operation involving heat, or overhaul, check that operating pressures, flames or sparks on a machine, the surrounding... -
Page 13: Specific Safety Precautions
SPECIFIC SAFETY PRECAUTIONS Pressure vessels (Pressure) vessel maintenance is to be performed by Atlas Copco. Maintenance/installation requirements: Batteries The vessel can be used as pressure vessel or as When servicing batteries, always wear protecting separator and is designed to hold compressed air Safety valves clothing and glasses. -
Page 14: Leading Particulars
Leading particulars GENERAL DESCRIPTION The XRYS 577 - XRYS 1260 is a silenced, two-stage, Engine Regulation XRYS compressor oil-injected screw compressor, built for a nominal The compressors are driven by a 6 cilinder in-line The compressor is provided with a dual pressure effective working pressure of 35 bar (510 psi). - Page 15 Cooling system Bodywork Exhaust system The engine is provided with a liquid-cooler and The bodywork has openings for the intake and outlet The exhaust system includes a new exhaust intercooler and the compressor is provided with an oil of cooling air and hinged doors for maintenance and aftertreatment system that meets strict installation cooler.
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Page 16: Main Parts
Main parts (OC) (BF) (FC) (CLS) (FCc) (FFp) (FFp) (FFp) (FFf) (TB) (FFf) (IC) (BH) (AFe) (OT) (DPF) (BS) (BS) (OFce) (OFce) (AFce) (CU) (CU) (SV) (SN) (AR) (FPco) (OLG) (MPV) (RVhp) (LV) (RV) (RVlp) (TShp) (LV) (PSS) (FT) (CEhp) (DPar) (DPce) (FL) - Page 17 Reference Name Reference Name Reference Name AFce Air Filter (compressor element) Exhaust Pipe RVhp Regulating Valve (high pressure) (XRXS) Air Filter (engine) RVlp Regulating Valve (low pressure) Air Outlet Valves Fuel Cooler (XRXS) Air Receiver Filler Cap (coolant) Serial Number AirXpert Stepper Valve (XRYS) Fuel Prefilter Safety Valve...
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Page 18: Regulating System
REGULATING SYSTEM OVERVIEW XRYS (AFe) (AFE) (SC) (AFS) (AFc) (DE) (OT) (BVof) (OFc) (TBV) (OC) (SL) (WPS) (SV) (BOsv) (PSai) (OSE) (DAXiv) (DAXsm) (AR) (CH) (MPV) (OFe) (DP) (CElp) (DAXc) (PSlp) (AOV) (TShp) (OSV) (EW) (TSlp) (CU) (CEhp) - 18 -... - Page 19 Reference Name Reference Name Air Filter Element Oil Separator Element Oil Stop Valve Air Filter (compressor) Oiltronix Air Filter (engine) PSai Pressure Sensor (air inlet) Air Filter Switch PSlp Pressure Sensor (low pressure) Air Outlet Valve Safety Cartridge Air Receiver Scavenge Line BVof Bypass Valve oil filter...
- Page 20 Reference Name XRXS AFce Air Filter (compressor element) (AFe) Air Filter Element (AFE) (SC) Air Filter (engine) (AFS) Air Filter Switch (AFce) (DE) Air Outlet Valves (OT) Air Receiver (BVof) (OFce) Blow Off Valve (TBV) BVof Bypass Valve oil filter (SL) Cubicle (WPS)
- Page 21 Reference Name XRVS Minimum Pressure Valve (AFe) (AFE) Oil Cooler (SC) OFce Oil Filter (compressor element) (AFS) Oil Filter (engine) (AFce) Oil Separator Element (DE) Oil Stop Valve (BVof) (OFce) Oiltronix (TBV) PSlp Pressure Sensor (low pressure) Pressure Selection Switch Regulating Valve (SL) (OC)
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Page 22: Air Flow (All Units)
AIR FLOW (ALL UNITS) OIL SYSTEM (ALL UNITS) Air drawn through the airfilter (AFce) into the The lower part of the air receiver (AR) serves as an oil The oil filter by-pass valve (BVof) opens when the compressor element (CElp CEhp) is compressed. At tank. -
Page 23: Continuous Pneumatic Regulating System (Xrvs + Xrxs)
ELECTRONIC REGULATING SYSTEM (XRYS) CONTINUOUS PNEUMATIC REGULATING SYSTEM (XRVS + XRXS) The compressor is provided with a continuous If the air consumption is less than the maximum air To be able to control pressure and flow the AirXpert pneumatic regulating system and a blow-off valve output, air receiver pressure increases and the system watches: (BOV), which is integrated in the unloader assembly... -
Page 24: Flow Diagram Exhaust Aftertreatment
FLOW DIAGRAM EXHAUST AFTERTREATMENT (HPFP) (DOC) (EAM) (DPF) - 24 -... -
Page 25: Exhaust Gas Aftertreatment (All Units)
CO filter. The exhaust gas is fully automatically cleaned. ash. Atlas Copco engines use high temperature The process is monitored by the machine controller. regeneration that includes a fuel burner in the exhaust stream that intermittently raises the temperature above 600º... -
Page 26: Electric System
ELECTRIC SYSTEM CIRCUIT DIAGRAM INDEX 9822 0963 68 Desc. 1 Desc. 2 Sheet Col. Desc. 1 Desc. 2 Sheet Col. Namur sensor Bypass Solenoid Starter motor Namur sensor Closed Relay Fuel priming pump Combo sensor Relay Remote control Namur sensor Bypass Relay Roof actuator... - Page 27 9822 0963 68 Desc. 1 Desc. 2 Sheet Col. Desc. 1 Desc. 2 Sheet Col. ΔP airfilter Pressure switch Connector XC3003/4003 primary Pressure sensor Vessel pressure X10A Connector Air shut-off valve Pressure sensor Regulating pressure X10B Connector Preheater Pressure sensor Interstage pressure X10C Connector...
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Page 28: Sh3 Engine Circuit
SH3 ENGINE CIRCUIT 9822 0963 68 - 28 -... - Page 29 Reference Name Engine PAC CCM CAN Bus CAN End Resistor Compressor PAC Relay for CRS Power Diagnostic Relay for CRS Pump CAT Interconnect 12 Pole STD Engine - 29 -...
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Page 30: Sh4 Compressor Circuit
SH4 COMPRESSOR CIRCUIT 9822 0963 68 - 30 -... -
Page 31: Sh5 Compressor Control Module
SH5 COMPRESSOR CONTROL MODULE 9822 0963 68 Reference Name Customer Remote Installation - 31 -... -
Page 32: Sh6 Optional Equipment
SH6 OPTIONAL EQUIPMENT Reference Name 9822 0963 68 Refuel Pump Air Discharge Sensors Air shut-Off Valve Aftercooler Fans - 32 -... - Page 33 Reference Name 9822 0963 68 Blow Down Valve Aftercooler Air Discharge Sensors External Fuel Switch - 33 -...
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Page 34: Sh7 Optional Equipment
SH7 OPTIONAL EQUIPMENT 9822 0963 68 Reference Name Preheater (+ Arctic) Oiltronix - 34 -... - Page 35 9822 0963 68 Reference Name Etherstart Remote Control 7-D Remote Control Remote Off/On Remote Start Remote Stop Remote Load/No Load GND for digital inputs Remote DC Power Supply Remote Off/On GND for digital inputs Remote DC Power Supply + - 35 -...
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Page 36: Sh8 Optional Equipment
SH8 OPTIONAL EQUIPMENT 9822 0963 68 Reference Name Internal Lights Roof Actuator Option Box - 36 -... -
Page 37: Fuse Box
FUSE BOX 9822 0963 68 Reference Name Dual Preset/Pressure AirXpert Reference Name Main circuit breaker Engine control module CAT regeneration system Fuel priming pump Refuel pump Internal lights Preheater/Nordic Roof actuator Charging alternator - 37 -... -
Page 38: Undercarriage
UNDERCARRIAGE WAGON The wagon undercarriage is equipped with a parking brake only. It consists of drum brakes installed on the rear wheels and a lever that is connected through a steel wire linkage to the brakes. The parking brake is applied by moving a lever (10) in the direction of the arrow. -
Page 39: Tandem Eu
TANDEM EU Product description Compressors with EU tandem undercarriage are intended to be transported hooked up with a truck. The undercarriage has low-maintenance axles with parabolic suspension and air brakes with ABS and ALB regulator. The installed cilinders have integrated parking and emergency brakes. - Page 40 Brake System Manual operation of brake system Functional Description To activate the parking brake, pull the red button (1) until it snaps into place. To release the parking brake compressor's service brake comes press the button (1). By activating and releasing the automatically when uncoupling the feed line from the parking brake the air pressure in the system drops.
- Page 41 Emergency release of spring-loaded parking brake Put the loose thread bolt with the profile at the end in Now using the wrench, tighten the nut and thus Reference Name the opening of the spring brake. Turn the thread bolt compressing the spring and releasing the brake. You around approximately 90°.
- Page 42 Plug connections (15-pin) Function Cable cross section Line colour Left light indicator 1.5 mm yellow Right light indicator 1.5 mm green Rear fog light 1.5 mm blue Ground connection 2.5 mm white Left rear outline light, license plate illumination 1.5 mm black Right rear outline light, running light, license plate illumination 1.5 mm brown...
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Page 43: Markings And Information Labels
Fork lifting permitted. Read the instruction manual before Electrocution hazard. Don’t lift here. starting. Read the instruction manual before Atlas Copco synthetic compressor oil. Service every 24 hours. lifting. Atlas Copco mineral engine oil. Warning! Part under pressure. Filler cap coolant. -
Page 44: Operating Instructions
Operating instructions GENERAL SAFETY INSTRUCTIONS For coupling always drive the truck towards the Do not drive diagonally up a slope. PARKING, TOWING AND LIFTING compressor. When driving on slopes in an extremely slanted INSTRUCTIONS Accidents may be caused when you allow the position the compressor may roll over. -
Page 45: High Speed Eu Tandem
HIGH SPEED EU TANDEM Always replace damaged tow bars or towing eyes Secure the support legs crank before each trip. ones! Welding structural If the crank is not secured before the trip, the stand modifications are not permissible. may lower itself during the trip. Repairs of the tow bar or towing eye may lead to As a result of related accidents people may get operational failure. - Page 46 TANDEM EU Locate the rear-end of the compressor upwind, away Uncouple vehicle. When removing the compressed air hoses, the from contaminated wind-streams and walls. Do not compressor's service brake is activated automatically. Apply parking brake by moving the lever (1) in the obstruct air evacuation from the cooling system.
- Page 47 Release the support lock (1), turn the support leg Release the support lock (1), turn the support leg Only operate the parking brake when it vertically and secure it. vertically and secure it. is cold. Undo the latch (2) and lower the support leg using the Take out the locking pin (2) and lower the support leg Using the parking brake when the crank (3).
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Page 48: Towing Instructions
TOWING INSTRUCTIONS WAGON TANDEM EU Towbar levelling Before towing the compressor, ensure Before towing the compressor, ensure that the towing equipment of the vehicle that the towing equipment of the vehicle The towbar of the wagon is equipped with an matches the towing eye. - Page 49 Ensure that the support leg has been Ensure that the support leg has been Ensure that the ladder leg has been fully fully raised, and folded upwards prior to fully raised, and folded upwards prior to folded up and secured prior to each trip. each trip.
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Page 50: Lifting Instructions
Coupling the compressor LIFTING INSTRUCTIONS Now connect the compressor's connections to the vehicle. Follow the correct sequence when making the connections. 1. First connect the power supply and the compressor 's ABS plug to your vehicle. Secure these by fitting the locking bracket. 2. -
Page 51: Internal Lighting
INTERNAL LIGHTING PREHEATER (OPTION) When an emergency stop has to be performed: Before performing any maintenance jobs always switch off the preheater and • Switch off the preheater at the control element remove the fuse or disconnect the heater • Remove the fuse or disconnect the heater from the from the battery. -
Page 52: Operations Overview
OPERATIONS OVERVIEW General Setting pre-settings • When no button is pressed the display will return • By pressing button (1) once, twice or three times to its default mode - normal time display. you will select pre-set time 1, 2 or 3. •... -
Page 53: Before Starting
BEFORE STARTING 5. Check the level of the compressor oil. See section Check compressor oil level. The pointer of the oil level gauge (OLG) should register in the green range. Add oil if necessary. See section Compressor oil for the oil to be used. Before removing oil filler plug (FP), ensure that the pressure is released by opening an air outlet valve. -
Page 54: Basic Operation Of The Machine
BASIC OPERATION OF THE MACHINE STARTING / STOPPING BATTERY SWITCH The compressor can be controlled in 4 different The compressor is equipped with a battery switch. Safety precautions modes: When the compressor is not in use this switch must Do not disconnect power supply to •... -
Page 55: Control Panel
CONTROL PANEL Reference Name POWER OFF / ON switch To switch the control panel on and off START button Pressing this button will start the compressor. STOP button Pressing this button will stop the compressor in a controlled way. - 55 -... - Page 56 Reference Name LOAD button. Pressing this button will: • initiate the Auto Load function, or commands the compressor to load (depending on actual status). • command the compressor to switch to Not Loaded (when in Load). MEASUREMENTS VIEW button By pressing this button you can toggle between Measurements View and Main View.
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Page 57: Overview Icons
OVERVIEW ICONS Reference Name Compressor status Vessel pressure indication or info text Compressor info Main View Indication Measuring View Indication Settings View Indication MAIN VIEW LOADED Alarm View Indication DPF REGENERATION High Exhaust System Temperature. Means that the Diesel Particle Filter is being regenerated. - Page 58 Reference Name Reference Name Reference Name DPF REGENERATION OPERATION MODE FUELTANK Diesel Particle Filter Regeneration Local Running at internal fueltank. Inhibited. Means that the DPF regeneration is OPERATION MODE FUELTANK inhibited, even if all criteria to Remote Running at internal fueltank & activate a regeneration are met.
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Page 59: Possible Views
POSSIBLE VIEWS Main View Setup View Alarm View SETTINGS ALARMS LOADED LOADED 1000 GENERAL SETTINGS 3450 BATTERY LOW ALARM 2000 DIGITAL INPUTS 2070 COOLANT LEVEL LOW 3000 VOLTAGE INPUTS 3010 FUEL LEVEL LOW 4000 TEMPERATURE INPUTS ECU DM1 LIST 5000 RELAY OUTPUTS ECU DM2 LIST 5300 SEMICONDUCTOR OUTPUTS EVENT LOG LIST... -
Page 60: Starting
STARTING The display now shows Switch on the battery switch. Switch the controller on by switching the Power MAIN VIEW MAIN VIEW switch to the position “ON”. VESSEL BLOWING DOWN PREPARING FOR START The instrument panel will now perform a selftest; the following display will be shown and the controller is initialized: 1286h... - Page 61 The display now shows The display now shows MAIN VIEW MAIN VIEW MAIN VIEW PREPARING FOR START READING ENGINE DATA ENGINE PREHEATING 1286h --RPM 0.0bar 1286h --RPM 0.0bar 1286h --RPM 0.0bar After pressing the START button the machine will The engine electronics (ECU) will be powered up. activate its horn and flasher light for 5 seconds, to Active Buttons As soon as communication between compressor...
- Page 62 The engine starts crancking, the display shows The display now shows The engine starts running at idle speed. The display shows MAIN VIEW MAIN VIEW MAIN VIEW ENGINE CRANKING ENGINE RESTING ENGINE WARMING UP 13˚C 40˚C 0RPM 800RPM 120s 25˚C 324RPM 300s 1286h...
- Page 63 The display now shows After warming up the machine is ready to be loaded and is waiting for a load command; the display shows MAIN VIEW MAIN VIEW ENGINE WARMING UP READY TO LOAD 1286h 1200RPM 2.9 bar 1286h 1200RPM 4.6bar Active Buttons Active Buttons...
- Page 64 Press the load button, the display will show The engine will now run at maximum rpm, the display During loading the following display is shown will show (default display) MAIN VIEW MAIN VIEW MAIN VIEW LOADED BUILDING UP VESSEL PRESSURE PREPARING TO LOAD 18.6 1286h...
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Page 65: Stopping
During operation STOPPING The doors must be closed during After pressing the STOP button the display will show: operation and may be opened for short periods for inspection and adjustments only. MAIN VIEW MAIN VIEW ENGINE COOLING DOWN ENGINE COOLING DOWN Be aware not to touch hot parts when the door is open. -
Page 66: Shutdown
SHUTDOWN POWER OFF After cooling down the engine will stop and the When the machine is shutdown due to a critical alarm Switch the controller off by switching the Power display will show or an emergency stop the display will show switch to the position “OFF”. -
Page 67: Diesel Particulate Filter Regeneration
DIESEL PARTICULATE FILTER AUTOMATIC DPF REGENERATION REGENERATION (DEFAULT) When the Diesel Particle Filter regeneration process In specific cases, when the engine speed is constant at If Enter is pressed within 10 seconds then the is kept at its default ‘AUTOMATIC’ setting, then the Minimum RPM, it can happen that the DPF controller will allow the DPF regeneration to be DPF regeneration will be performed automatically... -
Page 68: Inhibit Dpf Regeneration
INHIBIT DPF REGENERATION INCREASING SOOT LOAD When running in an environment where an elevated When the DPF Regeneration is Inhibited, or when the SOOT LOAD reaches 90% (only when DPF Regeneration is Inhibited) exhaust temperature is not allowed, it might be engine does not get sufficient possibility to necessary to inhibit DPF regeneration. - Page 69 Regeneration Needed icon will disappear (engine electronics are powered down).. 7110 LOAD PREVENTION - HIGH DPF SOOT LO... Required Action: Contact Atlas Copco for further actions • Acknowledge the ‘ECU DPF SOOT LOAD Required Action: to be taken. HIGH’ warning (press Enter while in the Main •...
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Page 70: Force Dpf Regeneration
FORCE DPF REGENERATION If DPF Regeneration is Inhibited Machine is not running: Power the controller down. At next power up, the DPF Regeneration settings will be back to default, and an Automatic DPF Regeneration will take place at the soonest appropriate moment. Machine is running: •... -
Page 71: Settings
SETTINGS For buttons to be used see “Control Panel” As long as there is an alarm icon in the middle of the Set Language bottom part of the view, all active acknowledged / un- Press the SETTINGS VIEW button. Acknowledge an Alarm acknowledged alarms can be seen by pressing the •... - Page 72 Change Display Settings Set the Pressure/Flow Setpoint Set the AutoLoad Function (only on AirXpert machines) Press the SETTINGS VIEW button Press the SETTINGS VIEW button When the controller is in the Main View (shift • scroll to ‘1000 GENERAL SETTINGS’ •...
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Page 73: Fault Codes
FAULT CODES There are several parameters that are continuously When one of these parameters exceeds its specified watched. limit the compressor will react depending the present status of the control box. Alarmcode Alarmtext Failclass Trigger 1231 FUEL FILL CHECK Warning 1503 INITIAL OVERHAUL REQUIRED Warning... - Page 74 Alarmcode Alarmtext Failclass Trigger 3320 INLET PRESSURE SENSOR CIRCUIT Shutdown 3450 BATTERY LOW ALARM Indication 3460 BATTERY HIGH ALARM Warning 3660 FIRE RISK - CHECK OILSTOPVALVE Shutdown 3680 OSV PRESSURE SENSOR CIRCUIT Controlled Stop 3720 INTERSTAGE PRESSURE SENSOR CIRCUIT Warning 4000 L.P.
- Page 75 Warning 7110 PLEASE FORCE DPF REGENERATION ! Inhibit Load 7120 LOAD PREVENTION - HIGH DPF SOOT LOAD Controlled Stop 7130 SOOT LOAD TOO HIGH - CALL ATLAS COPCO Warning 7222 COMBO COMMUNICATION FAILURE Warning 7223 COMBO PA SENSOR WARNING Warning...
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Page 76: Starting / Stopping Via Remote Control
STARTING / STOPPING VIA REMOTE EMERGENCY STOP CONTROL The emergency stop button is only to be Always use the remote control function accordance local/work area used in emergency situations; not for stopping procedures. legislation. When an emergency stop button (1) is pressed, power to all outputs is terminated, by the emergency stop 1 Start Engine itself (hardware) as well as by the software. -
Page 77: Maintenance
Service Paks minimize downtime and keep your protective measures must be taken. maintenance budget low. Order Service Paks at your local Atlas Copco dealer. - 77 -... -
Page 78: Preventive Maintenance Schedule
2912 4559 06 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 a reduced price, compared to individual components. Refer to the parts list for more information on the contents of the service kits. - Page 79 Daily 50 hrs Every Every Every Every Every Yearly Maintenance schedule (hrs) after initial 250 hrs 500 hrs 750 hrs 1000 hrs 2000 hrs (continuation of page 78) start-up Check coolant level Check/Fill fuel level (3) Check function of coolant heater (option) Check control panel Check on abnormal noise Check electrical system cables for wear...
- Page 80 Clean fuel cooler Clean crankcase breather filter and check for obstructions Replace air filter element (1) Check external fuel connection (option) Inspection by Atlas Copco service technician Adjust engine inlet and outlet valves (2) Inspect alternator Replace spring check valve...
- Page 81 6. Gummed or clogged filters means fuel starvation and reduced engine performance. 7. See section Oil specifications. 8. The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing points: • 2913 0028 00 : refractometer •...
- Page 82 Daily 50 km Every Every Every Yearly Maintenance schedule (km) after initial 500 km 1000 km 2000 km (continuation of page 81) start-up Drain ABS vessel (option) Check coupling head Check tyre pressure Check height of adjusting facility Check torque of wheel nuts Grease coupling head, tow bar bearings at the housing of the overrun brake Check brake system (if installed) and adjust if necessary...
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Page 83: Inspection Schedule For Undercarriage Eu
INSPECTION SCHEDULE FOR UNDERCARRIAGE EU Inspection includes regular checks of individual After 50,000 km i.e. after 12 months of running, the The following details refer to normal use of the components and related action based on these checks. undercarriage of the compressor has to be inspected compressor based on a maximum of 50,000 km per Lubricating individual components is also part of on its operational reliability by an expert. -
Page 84: Oil Specifications
OIL SPECIFICATIONS PAROIL from Atlas Copco is the ONLY oil tested PAROIL has an excellent Total Base Number (TBN) It is strongly recommended to use Atlas and approved for use in all engines built into Atlas retention and more alkalinity to control acid Copco branded lubrication oils for both Copco compressors and generators. -
Page 85: Compressor Oil
COMPRESSOR OIL Synthetic compressor oil PAROIL S Liter US gal Order number 50˚ C 122˚ F 1630 0160 00 40˚ C 104˚ F 1630 0161 00 barrel 55.2 1630 0162 00 30˚ C 86˚ F container 1000 1630 0163 00 20˚... -
Page 86: Engine Oil
ENGINE OIL Synthetic engine oil PAROIL E xtra Liter US gal Order number 50˚ C 122˚ F 1630 0135 00 40˚ C 104˚ F 1630 0136 00 30˚ C 86˚ F Mineral engine oil PAROIL E Mission Green 20˚ C 68˚... -
Page 87: Oil Level Check
OIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL DIESEL FUEL RECOMMENDATIONS CHECK ENGINE OIL LEVEL Also consult the Engine Operation Manual for the oil specifications, viscosity recommendations and oil change intervals. For intervals, see Preventive maintenance schedule. Check engine oil level in accordance with the instructions in the Engine Operation Manual and if Ultra Low Sulfur Diesel (ULSD) fuel necessary, top up with oil. -
Page 88: Oil And Oil Filter Change
OIL AND OIL FILTER CHANGE TOPPING UP THE COMPRESSOR OIL Misfueling with fuels of higher sulfur level can ENGINE OIL AND OIL FILTER CHANGE have the following negative effects: See section Preventive maintenance schedule. • Shorten the time interval between aftertreatment device service intervals (cause the need for more frequent service intervals). -
Page 89: Compressor Oil And Oil Filter Change
Never add more oil. Overfilling results in In this case, contact Atlas Copco. oil consumption. - 89 -... -
Page 90: Compressor Oil Flushing Procedure
11. Collect all waste lubricant used during the Whenever aged oil is discovered, eg. when changing flushing process and dispose of it in accordance the oil separator, contact Atlas Copco Service dept. to with the applicable procedures for managing have your compressor cleaned and flushed. -
Page 91: Coolant Specifications
The system may be under pressure. overheating and possible failure. Remove the cap slowly and only when Atlas Copco's PARCOOL EG extended life coolant is coolant is at ambient temperature. A the new range of organic coolants purpose-designed It reduces water pump seal wear and has excellent sudden release of pressure from a heated to meet the needs of modern engines. -
Page 92: Handling Parcool Eg
PARCOOL EG is compatible with most other • A refractometer can be ordered from Atlas Copco injury from the splash of hot coolant. coolants based on ethylene glycol, but you only get the benefits of 5 years protection when its used on its with part number 2913 0028 00. -
Page 93: Topping Up Without Draining From The Cooling System
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/or graph: Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate Example: PN: 1604 8159 00 Total volume coolant =... -
Page 94: Topping Up After Limited Quantity Draining From The Cooling System
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 cooling system, can be estimated with the following formula and/ or graph: Corrections concentrate in measured system towards 50% volume by using PARCOOL EG Concentrate Example: PN: 1604 8159 00 Total volume coolant =... -
Page 95: Replacing The Coolant
• Using the Atlas Copco Instruction book, determine the amount of PARCOOL EG required Never leave spilled liquids such as fuel, and pour into the radiator top tank. -
Page 96: Battery Care
BATTERY CARE ACTIVATING A DRY-CHARGED BATTERY MAKE-UP DISTILLED WATER • Take out the battery. The amount of water evaporating from batteries is Before handling batteries, read the largely dependant on the operating conditions, i.e. • Battery and electrolyte must be at an equal relevant safety precautions and act temperatures, number of starts, running time between temperature above 10 °C (50 °F). -
Page 97: Periodic Battery Service
• Keep the battery clean and dry. When a compressor element is due for overhaul, it needs to be done by Atlas Copco. This guarantees the • Keep the electrolyte level at 10 to 15 mm above use of genuine parts and correct tools with care and the plates or at the indicated level;... -
Page 98: Adjustments And Servicing Procedures
Adjustments and servicing procedures Single pressure system (XRVS) ADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM The working pressure is determined by the tension of the spring in the regulating valve (RV). This tension can be increased to raise the pressure and decreased by turning the adjusting wheel clockwise and anti- clockwise respectively. -
Page 99: Air Filters Engine / Compressor
4. Inspect and tighten all air intake connections. 3. Safety cartridge 6. Vacuator valve The Atlas Copco air filters are specially designed for the application. The use of non-original air filters may lead to severe damage of the engine and/or compressor element. -
Page 100: Air Receiver
AIR RECEIVER SAFETY VALVE All adjustments or repairs are to be done by an authorized representative of the safety valve (2) supplier, see section Specific safety precautions. Following checks must be carried out: • A check of the opening of the lifting gear, twice a year. -
Page 101: Fuel System
FUEL SYSTEM Key-on priming (if equipped) Manual switch priming (if equipped) The manual switch is located on the primary filter Do not allow dirt to enter the fuel system. base/electric priming pump assembly. PRIMING INSTRUCTIONS Thoroughly clean the area around a fuel 1. -
Page 102: Replacing Filter Elements
REPLACING FILTER ELEMENTS BRAKE SYSTEM ADJUSTMENT Replacing the filter elements: Brake shoe adjustment Wagon Installation instructions: 1. Drain fuel from the bowl. 2. Remove filter (2, 3), filterelement (4) and separate bowl (2) from element (3). 3. Apply film of gas oil to new bowl seat. 4. -
Page 103: Brake Adjustment Wagon
BRAKE ADJUSTMENT WAGON Adjusting the linkage • The parking brake is adjusted by using the turnbuckle (8). Adjust till the play in the linkage is 1-3 mm (max. 3mm is allowed). • Apply the parking brake lever several times by hand with a force of 200 to 300 N and put it back into the -not engaged- tooth “1”... -
Page 104: Maintenance Undercarriage
MAINTENANCE UNDERCARRIAGE Support leg lubrication point Lubrication point of folding supports TANDEM EU Inspections and repair of the axles have to be performed by a skill level 2 truck work shop mechanical technician according applicable local regulations. Inspections, adjustment and repair of the brake system have to be performed by a skill level 2 truck work shop mechanical technician according to... - Page 105 Cleaning instructions filter element Draining the brake system Tyres Tyre check Check the tyre pressure and tread. Refer table chapter Technical specifications. Tyre change When changing tyres please pay attention to the following. Take direction of wheel travel into consideration. Check the tyre pressure.
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Page 106: Problem Solving
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. - Page 107 Possible faults Corrective actions Regulating valve (RV) opens too late or its ball valve spring is broken. Have regulating valve removed and inspected by an Atlas Copco Service representative. Air leaks in regulating system. Check hoses and their fittings. Stop leaks; replace leaking hoses.
- Page 108 Check and correct if necessary. Oil stop valve malfunctioning. Remove and inspect valve. Oil separator element (OS) clogged. Have element removed and inspected by an Atlas Copco Service representative. Alternator precautions 1. Never reverse the polarity of the battery or the alternator.
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Page 109: Undercarriage Tandem Eu
UNDERCARRIAGE TANDEM EU Malfunction: The compressor is constantly being braked. Possible faults Corrective actions The parking brake was not released. Release the parking brake. The brake system was not properly serviced. Visit a garage and have your brake system serviced. Failure of compressed air system. - Page 110 Malfunction: Whilst driving the compressor starts swerving quickly. Possible faults Corrective actions The tyre pressure is too high. Deflate the tyre until you reach normal tyre pressure. The driving speed is too high and not in accordance with the road Slow down.
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Page 111: Heater
Block the valve by screwing a bolt (M5 x 20) through the housing and in the blind hole in the coupling. Possible faults Corrective actions Device switched off and on again too many Contact your agent. Contact Atlas Copco for a thorough scan times. and repair. - 111 -... -
Page 112: Available Options
Available options UNDERCARRIAGE WAGON UNDERCARRIAGE TANDEM EU SUPPORT MOUNTED / LARGE FUELTANKS The undercarriage makes it possible to move the Easy transport & installation; High speed highway With the option “Support mounted” it is possible to compressor on the site with a truck to the location transport and easy manoeuvrability. - Page 113 SKID / LARGE FUELTANKS WHEEL CHOCKS ADDITIONAL FUELFILTER For extra safe parking on slopes. In dusty environments or in situations where the fuel quality is not up to the normal standard, this additional fuel filter gives an extra protection to the fuel/combustion system.
- Page 114 ELECTRIC REFUEL PUMP PREHEATER COLD WEATHER PACKAGE The electric refuel pump makes it easy to refuel the The preheater is a device for preheating the cooling The cold start option consists of larger batteries compressor on site when refuelling from tanks or fluid before starting when operating at low and a blow off valve to be able to start the engine containers.
- Page 115 INLET SHUTDOWN VALVE EXTERNAL FUEL CONNECTION INTERNAL LIGHTING When a compressor is operated on site for a longer The internal lighting circuit is equipped with a timer. period it is advisable to supply the fuel through When the internal lighting is switched on, the timer is external fuel connections.
- Page 116 REGULATING SYSTEM SINGLE PRESSURE REGULATING SYSTEM DUAL PRESSURE REGULATING SYSTEM DUAL PRESSURE FUEL EXPERT NO FUEL EXPERT FUEL EXPERT This is a control module that regulates engine speed and the air inlet to optimise fuel consumption depending on the working conditions, and the output required.
- Page 117 PRESSURE REGULATOR EC PRESSURE REGULATOR ASME FORK LIFT SLOTS With fork lift slots the compressor can easily be moved with a fork lift truck on building sites where it is impossible to use a towing truck. A pressure regulating system according to European A pressure regulating system according to US standards for reducing the operating pressure.
- Page 118 AFTER-COOLER REMOTE START A warning can be set at a value between 0°C and 115°C (=default value) and a shut-down can be set at a value between 0°C and 120°C (= default value). The operator has authority to modify these values so the process can be guarded and kept in a safe condition under all circumstances.
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Page 119: Technical Specifications
Technical specifications TORQUE VALUES GENERAL TORQUE VALUES CRITICAL TORQUE VALUES The following tables list the recommended torques applied for general applications Assemblies Torque value (Nm / lbf.ft) during assembly of the compressor. Axles to frame: Wheel nuts 270 (200) For hexagon screws and nuts with strength grade 8.8 Bolts, front axle/frame 205 (152) Bolts, rear axle/frame... -
Page 120: Compressor / Engine Specifications
COMPRESSOR / ENGINE SPECIFICATIONS REFERENCE CONDITIONS Designation XRYS 577 - XRYS 1260 XRXS 607 - XRXS 1275 XRVS 647 - XRVS 1350 Absolute inlet pressure bar(e) 14.5 14.5 14.5 Relative air humidity Air inlet temperature °C °F Nominal effective working pressure bar(e) The inlet conditions are specified at the air inlet grating outside the canopy. -
Page 121: Performance Data
PERFORMANCE DATA At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated. Designation XRYS 577 - XRYS 1260 XRXS 607 - XRXS 1275 XRVS 647 - XRVS 1350 Engine shaft speed, normal and maximum at 22 bar (320 psi) pressure setting... - Page 122 Designation XRYS 577 - XRYS 1260 XRXS 607 - XRXS 1275 XRVS 647 - XRVS 1350 Fuel consumption - at 100% FAD at 25 bar (363 psi) kg/h 86.2 86.2 pressure setting lb/h 190.0 190.0 at 30 bar (435 psi) kg/h 81.2...
- Page 123 Designation XRYS 577 - XRYS 1260 XRXS 607 - XRXS 1275 XRVS 647 - XRVS 1350 Specific fuel consumption without aftercooler 36.9 36.5 at 100% FAD lb/1000 cu.ft 2.30 2.27 at 25 bar (363 psi) with aftercooler 38.1 38.1 pressure setting lb/1000 cu.ft...
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Page 124: Altitude Unit Performance Curve
ALTITUDE UNIT PERFORMANCE CURVE Max. achievable working pressure in relation to altitude and ambient temperature. Graph represents working conditions, for starting conditions please contact your Atlas Copco contact. Temperature °F Temperature °F 3000 3000 9000 9000 2500 2500 8000 8000... - Page 125 Temperature °F 3000 9000 2500 8000 7000 2000 6000 5000 1500 25 bar 363 psi 4000 1000 3000 2000 1000 Temperature °C XRVS 647 - XRVS 1350 - 125 -...
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Page 126: Design Data
All units Number of compression stages Capacity of oil sump: - Initial fill Engine US gal 16.9 - Refill (max.) Designation XRYS 577 - XRXS 607 - XRVS 647 - XRYS 1260 XRXS 1275 XRVS 1350 US gal 16.4 Make... - Page 127 Unit Electric refuel pump Designation All units Designation All units Capacity of compressor oil system Flow rate US gal 21.7 US gal/m Net capacity of air receiver Self priming from dry up to US gal 37.8 Capacity of fuel tank (wagon) Fuel temperature max 40 °C (104 °F) US gal Capacity of fuel tank (tandem)
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Page 128: Unit Dimensions
UNIT DIMENSIONS 9822 0831 51 - C18 T4A Wagon 9822 0831 53 - C18 T4A Skid mounted 2251 NATO TOWING EYE 6516 SWE TOWING EYE 6612 2251 4562,5 DIN TOWING EYE 6614 9822 0831 52 - C18 T4A Support mounted 9822 0831 54 - C18 T4A EU Tandem 2251 2246... -
Page 129: Dataplate
Dataplate Company code Product code Unit serial number Atlas Copco Airpower n.v. Name of the manufacturer EEC or national type approval number Vehicle identification number Undercarriage A Maximum permitted total weight of the vehicle B Maximum permitted load on towing eye... -
Page 130: Legislation
Legislation PARTS, SUBJECTED TO PRESSURE EQUIPMENT DIRECTIVE 97/23/EC, CAT. II AND ABOVE Safety valve: cat. IV Designation XRYS 577 - XRYS 1260 XRXS 607 - XRXS 1275 XRVS 647 - XRVS 1350 Set pressure bar(e) Design temperature °C °F Air Oil separator... -
Page 131: Parts, Subjected To Cat. I And Covered By The Machine Directive 89/392/Ec
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 - 131 -... -
Page 132: Disposal
(for example sand, sawdust) non- recyclable materials. and dispose of it in accordance with local disposal Your Atlas Copco compressor consists for the most regulations. Do not drain into the sewage system or part of metallic materials, that can be remelted in surface water. -
Page 133: Maintenance Log
Maintenance Log Compressor ..................Customer ....................Serial number........................................Service hours Maintenance action Date By: initials - 133 -... - Page 134 Following documents are provided with this unit: - Test Certificate - EC Declaration of Conformity: EC DECLARATION OF CONFORMITY We, Atlas Copco Airpower n.v., declare under our sole responsibility, that the product Machine name Commercial name : Serial number Which falls under the provisions of article 12.2 of the EC Directive 2006/42/EC on the approximation of the laws of the Member States relating to machinery, is in conformity with the relevant Essential Health and Safety Requirements of this directive.