Related Manuals for Atlas Copco XA(S) 137 DD
Summary of Contents for Atlas Copco XA(S) 137 DD
- Page 1 Atlas Copco Instruction Manual Instruction Manual for Portable Compressors English XA(S) 137 DD - XA(S) 300 DD7 Engine Deutz XA(S) 137 DDG - XA(S) 300 DD7G BF4M2011 XAHS 107 DD - XAHS 250 DD7...
- Page 3 Instruction Manual for Portable Compressors XA(S) 137 DD - XA(S) 300 DD7 XA(S) 137 DDG - XA(S) 300 DD7G XAHS 107 DD - XAHS 250 DD7 Printed matter N° 2954 3170 01 ATLAS COPCO - PORTABLE AIR DIVISION www.atlascopco.com 04/2008...
- Page 4 The manufacturer does not accept any liability for any damage arising for modifications, additions or conversions made without the manufacturer's approval in writing. While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors.
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Page 5: Table Of Contents
Preface Table of contents Starting/Stopping ........28 4.2.1 Before starting ........28 Please read the following instructions carefully 4.2.2 Control panel (with cold start; option)... 28 before starting to use your compressor. Safety precautions for portable 4.2.3 Control panel (without cold start)..30 compressors with generator ...... - Page 6 Adjustments and servicing procedures .. 42 9.3.5 Design data for generator....... 64 Adjustment of the continuous Data plate ..........65 regulating system........42 Air filter engine/compressor....... 44 Disposal ............. 66 6.2.1 Servicing ..........44 11.1 General ............66 6.2.2 Main parts ..........44 11.2 Disposal of materials........
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Page 7: Safety Precautions For Portable Compressors With Generator
To be read attentively and acted accordingly before towing, lifting, operating, performing maintenance or repairing the unit. 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 Normal ratings (pressures, temperatures, speeds, 13 In the event the safety labels are damaged or damage arising from the use of non-original parts and etc.) shall be durably marked. destroyed, they must be replaced to ensure for modifications, additions or conversions made operator safety. -
Page 9: Safety During Transport And Installation
SAFETY DURING TRANSPORT AND To tow a unit use a towing vehicle of ample 11 Locate the unit away from walls. Take all capacity. Refer to the documentation of the precautions to ensure that hot air exhausted from INSTALLATION towing vehicle. the engine and driven machine cooling systems cannot be recirculated. - 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.
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Page 11: Safety During Maintenance And Repair
SAFETY DURING MAINTENANCE AND appropriate protection, at least safety glasses, for 30 Never touch the power terminals during operation the operator as well as for any bystander. Do not of the machine. REPAIR apply compressed air or inert gas to your skin or 31 Whenever an abnormal condition arises, e.g. -
Page 12: Tool Applications Safety
Atlas Copco or the cartridge is used and that its useful service life is machine manufacturer. Ascertain that the not surpassed. selected lubricants comply with all applicable... -
Page 13: Specific Safety Precautions
SPECIFIC SAFETY PRECAUTIONS Pressure vessels Safety valves (according to directive 87/404/EEC annex II § 2) All adjustments or repairs are to be done by an Batteries authorized representative of the valve supplier (see Maintenance/installation requirements: When servicing batteries, always wear protecting also Preventive maintenance schedule for the The vessel can be used as pressure vessel or as clothing and glasses. -
Page 14: Leading Particulars
The vessel is provided with an oil level indicator. Regulation The compressors type XA(S) 137 DD - XA(S) 300 DD7, XA(S) 137 DDG - XA(S) 300 DD7G and The compressor is provided with a continuous XAHS 107 DD - XAHS 250 DD7 are silenced,... - Page 15 Cooling system Bodywork Generator - XA(S) 137 DDG - XA(S) 300 DD7G The engine is equipped with an oil cooler. All The bodywork has openings at the shaped front and The built-in generator is driven by a multi V-belt compressors are equipped with an oil cooler. rear end for the intake and outlet of cooling air and drive.
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Page 16: Main Parts
(OLG) (FF) (AR) (FCeo) (AOV) (DSe) (OFce) (FCft) (CE) (VV) (FT) (AF) XA(S) 137 DDG - XA(S) 300 DD7G, XA(S) 137 DD - XA(S) 300 DD7 and XAHS 107 DD - XAHS 250 DD7 with some options - 14 -... - Page 17 Reference Name Reference Name Alternator OCce Oil Cooler (compressor element) Air Filter Oil Cooler (engine) Air Outlet Valves OFce Oil Filter (compressor element) Air Receiver Oil Level Gauge (compressor element) Brake Handle Regulating Valve Compressor Element Safety Valve Control Panel Towbar Control Panel Generator Vacuum Indicator...
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Page 18: Compressor Regulating System
COMPRESSOR REGULATING SYSTEM OVERVIEW (LOAD CONDITION) Reference Name AFce Air Filter Compressor/Engine Air Filter Element Air Outlet Valves (AFE) Air Receiver/Oil Separator (AFce) (VI) Blow Down Valve By-Pass Valve Oil Filter (CV) (OC) Compressor Element (RV) (AR) Coupling Housing (SV) Control Panel (OSE) Check Valve... -
Page 19: Air Flow
AIR FLOW OIL SYSTEM The system comprises: The system comprises: Reference Name AFce Air filter compressor/engine AR/OSE Air receiver/oil separator Scavenge Line AR/OSE Air receiver/oil separator element Speed Regulator Element Oil cooler Compressor element Safety Valve Oil filter UA/UV Unloader assembly with unloader valve Temperature Switch Engine The lower part of the air receiver (AR) serves as oil Blow-down valve... -
Page 20: Continuous Regulating System
CONTINUOUS REGULATING SYSTEM (SVa) (RV) (BOV) (UV) (UA) (SR) (VH) (AR) (CE) - 18 -... - Page 21 The system comprises: If the air consumption is equal to or exceeds the maximum air output, the engine speed is held at Regulating valve maximum load speed and the unloading valve is fully Unloader assembly open. Speed regulator If the air consumption is less than the maximum air output, the regulating valve supplies control air to The compressor is provided with a continuous unloader valve (UV) to reduce the air output and...
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Page 22: Electrical System
ELECTRICAL SYSTEM All compressors are equipped with a negative earthed system. (9822 0841 15) Cold Start Option. Auxiliary - 20 -... - Page 23 Reference Name Circuit breaker Alternator Battery Lamp temperature alarm Lamp general alarm Starter solenoid (part of M1) Relay Relay Relay Relay K5-K6 Relay heater plug Starter motor Hourmeter P2-P3 Heater plug Contactswitch (Off-On-Override- Start) Temperature switch engine Oil pressure switch Temperature Lamptest switch Temperature switch compressor Coldstart switch...
- Page 24 X1.2 X1.1 X1.3 L3 N L3 N L3 N XA(S) 137 DDG - XA(S) 300 DD7G c0 c0 c0 c6 c0 c0 c0 c6 c0 c6 This generator is built to supply a sheer alternating current IT network. To Circuit diagram 9822 0797 01 R<...
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Page 25: Description
DESCRIPTION Reference Name Diode Generator function: Generator Turn switch S6 to position 1. The solenoid valve Y2G via the speed regulator SR controls the motor Lamp (Power control) and allows it to reach maximum speed (the normal Contactor 4-pole control system is switched off). Lamp H1 is Insulation Monitoring Relay activated (sockets X1.1, X1.2, X1.3 are under tension). -
Page 26: Markings And Information Labels
Do not run the compressor with open Danger, heat flat. Runlamp. doors. Electrocution hazard. Airfilter. Lifting permitted. Atlas Copco mineral compressor oil. Compressor temperature too high. Use diesel fuel only. 4.75 bar Atlas Copco synthetic compressor oil. Rotation direction. Tyre pressure. -
Page 27: Operating Instructions
Operating instructions PARKING INSTRUCTIONS PARKING, TOWING AND LIFTING INSTRUCTIONS Safety precautions The operator is expected to apply all relevant safety precautions, including those mentioned on the pages 5 - 11 of this book. Attention: Before putting the compressor in to use, check the brake system as described in section Brake (= option) adjustment. -
Page 28: Towing Instructions
TOWING INSTRUCTIONS Locate the rear-end of the compressor upwind, away Label on towbar from contaminated wind-streams and walls. Avoid recirculation of exhaust air from the engine. This Before towing the compressor, ensure causes overheating and engine power decrease. that the towing equipment of the vehicle matches the towing eye or ball connector and ensure that the service doors are closed and locked properly. -
Page 29: Height Adjustment
HEIGHT ADJUSTMENT LIFTING INSTRUCTIONS (with adjustable towbar) • Remove spring pin (1). • Release locking nut (2) with support tools (Extension tube 3). • Adjust required height of the towbar. • Tighten locking nut (2) by hand first. • Secondly tighten locking nut (2) with a tightening torque corresponding to table. -
Page 30: Starting/Stopping
STARTING/STOPPING CONTROL PANEL (WITH COLD START; OPTION) BEFORE STARTING 1. Before initial start-up, prepare battery for operation if not already done. See section Battery care. 2. With the compressor standing level, check the level of the engine oil. Add oil, if necessary, to the upper mark on dipstick. - Page 31 Starting procedure The control panel indicates receiver pressure (PG) accumulated operating hours (P1). Before starting open the air outlet valve(s) (see section Compressor regulating system, AOV) and push circuit breaker button (F1) once (open hood first). Circuit breaker button should now be in position B.
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Page 32: Control Panel (Without Cold Start)
CONTROL PANEL (WITHOUT COLD START) The control panel indicates receiver pressure (PG) accumulated operating hours (P1). Before starting open the air outlet valve(s) (see section Compressor regulating system, AOV) and push circuit breaker button (F1) once (open hood first). Circuit breaker button should now be in position B. - Page 33 Starting procedure 1. To start, turn start switch S1 clockwise to position 4. The start switch automatically springs back to 1, lamp H2 (general alarm lamp) will go on. position 1. 2. Check correct operation of alarm lamps H1 and Lamp H1 only will go on when the compressor H2 by pushing lamp test button S4.
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Page 34: Generator Function (Xas 137 Ddg - Xa(S) 300 Dd7G)
GENERATOR FUNCTION (XAS 137 DDG - XA(S) 300 DD7G) Fault situations and protective devices: (K8) • Open the left machine door and check that the circuit breakers are up. If the circuit breakers are down, put them up (switch them on). Circuit (S1) (K1) (X1.1) -
Page 35: During Operation
DURING OPERATION STOPPING PROCEDURE When the engine is running, the air outlet valves (ball valves) must always be put in a fully opened or fully closed position. 3 min Regularly carry out following checks: 1. That regulating valve (see section Main Parts, 1. -
Page 36: Maintenance
When servicing, replace all disengaged packings, e.g. environment and quality of maintenance. gaskets, O-rings, washers. Order Service Paks at your local Atlas Copco dealer. For engine maintenance refer to Engine Operation Manual. Maintenance schedule Daily... - Page 37 Maintenance schedule Daily Initially Every 500 hours Every 1000 hours (continuation of page 34) Torque of wheel nuts Check Check Check Brake system (if installed) Check/Adjust Check/Adjust Check/Adjust Safety valve Test Door hinges Grease Grease Coupling head and all its moving parts / shaft Grease Grease Joints of height adjustment adjustable towbar...
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Page 38: Lubrication Oils
PAROIL 15W40 4. 500 hours only valid when using PAROIL SAE 15W40. PAROIL from Atlas Copco is the ONLY oil tested PAROIL releases excess heat efficiently, whilst 5. In case of poor fuel quality, replace fuel and approved for use in all engines built into Atlas maintaining excellent bore-polish protection to limit filter more frequently. - Page 39 Mineral compressor oil PAROIL M Liter US gal Order number If you want to use another brand of oil, 1615 5947 00 consult the Engine Operation Manual. 1615 5948 00 barrel 55.2 1615 5949 00 It is strongly recommended to use Atlas Copco branded lubrication oils for both compressor and engine.
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Page 40: Oil Level Check
OIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL Never mix oils of different brands or types. Use only non-toxic oils where there is a risk of inhaling delivered air. CHECK ENGINE OIL LEVEL Consult also the Engine Operation Manual for the oil specifications, viscosity recommendations and oil change intervals. -
Page 41: Oil And Oil Filter Change
(3) again registers in the upper extremity of the green range. Reinstall and tighten the filler In this case, contact Atlas Copco. plug. 1. Run the compressor until warm. Close the outlet Never add more oil. Overfilling results in valve(s) and stop the compressor. -
Page 42: Cleaning Coolers
CLEANING COOLERS BATTERY CARE Steam cleaning in combination with a cleansing agent Before handling batteries, read the may be applied. relevant safety precautions and act accordingly. To avoid damaging the coolers, angle between jet and coolers should be If the battery is still dry, it must be activated as approx. -
Page 43: Activating A Dry-Charged Battery
When a compressor element is due for overhaul, it is operate the unloading and regulating components. recommended to have it done by Atlas Copco. This Close the air outlet valves after stopping. guarantees the use of genuine parts and correct tools RECHARGING A BATTERY with care and precision. -
Page 44: Adjustments And Servicing Procedures
Adjustments and servicing procedures ADJUSTMENT OF THE CONTINUOUS 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 to lower it by turning the adjusting wheel clockwise and anti-clockwise respectively. - Page 45 Z1 – Z2 XA(S) 137 DD - XA(S) 300 DD7 bar(e) 8.1 – 8.5 120.5 101.5 117.5 – 123.5 XA(S) 137 DDG - XA(S) 300 DD7G bar(e) 8.1 – 8.5 120.5 101.5 117.5 – 123.5 XAHS 107 DD - XAHS 250 DD7 bar(e) 13.4...
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Page 46: Air Filter Engine/Compressor
AIR FILTER ENGINE/COMPRESSOR MAIN PARTS CLEANING THE DUST TRAP Remove dust daily. The Atlas Copco air filters are specially designed for the application. The use of To remove dust from the dust trap pinch the vacuator non-genuine air filters may lead to valve (6) several times. -
Page 47: Replacing The Air Filter Element
REPLACING THE AIR FILTER ELEMENT In order to clean, position a pipe with an end bent by New elements must also be inspected for tears or approx. 90° on the end of a compressed-air pistol. The punctures before installation. pipe must be long enough to reach the bottom of the Discard the element (4) when damaged. -
Page 48: Air Receiver
AIR RECEIVER SAFETY VALVE FUEL SYSTEM All adjustments or repairs are to be done by an authorized representative of the valve supplier. Following checks must be carried out on the safety valve (2): • a check of the opening of the lifting gear, twice a year. -
Page 49: Brake (= Option) Adjustment
BRAKE (= OPTION) ADJUSTMENT BRAKE SHOE ADJUSTMENT Lift and support the compressor. Make sure that all Before jacking up the compressor, brakes are off (overrunbrake and hand brake lever). connect it to a towing vehicle or attach a The brake cables must be free from tension. Lock the weight of minimum 50 kg (110 lb) to the swivel cams of the wheel brake from the outside by means of a pin ∅... -
Page 50: Test Procedure Of Brake Cable Adjustment
TEST PROCEDURE OF BRAKE CABLE ADJUSTMENT Correct and wrong position of markings 1. Check if the towing eye rod of the overrun brake mechanism is in the outmost position. 2. Check if the adjustable towbar (= option) is in the actual towing position. -
Page 51: Brake Cable Adjustment
BRAKE CABLE ADJUSTMENT 1. With the towing eye pulled out in the outmost position and the hand brake lever in the downward (4) (2) position (see Figure), loosen the lock nuts (2). Turn adjusting nuts and brake cable nuts (4) clockwise until there is no slack in the brake mechanism. -
Page 52: Problem Solving
Fill fuel tank. 6. Compressor is loaded automatically to a. Air intake throttle valve stuck in opened position. a. Check and, if necessary consult Atlas Copco. full capacity after starting. b. Air leaks in regulating system. b. Check hoses and their fittings. Stop leaks; replace leaking hoses. - Page 53 Corrective actions 8. Engine does not speed up immediately a. Regulating valve defective. a. Check and, if necessary consult Atlas Copco. after compressor loading valve button b. Air intake throttle valve stuck in closed position. b. Check and, if necessary consult Atlas Copco.
- Page 54 Problem Possible faults Corrective actions 15. Engine overheating. a. Insufficient engine cooling. a. Relocate compressor. b. Engine oil cooler clogged externally. b. Clean engine oil cooler. Refer to section Cleaning coolers. 16. Compressor overheating. a. Insufficient compressor cooling. a. Locate compressor away from walls; when banked with other compressors, leave space between them.
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Page 55: Available Options
Aftercooler + water separator + fine filter Without towbar: Support (without undercarriage) PD + reheater (C) Towing eyes: Atlas Copco Aftercooler + water separator + fine filter DD + PD + reheater (C) Aftercooler + water separator + reheater Ball... -
Page 56: Technical Specifications
Technical specifications TORQUE VALUES FOR GENERAL APPLICATIONS FOR IMPORTANT ASSEMBLIES The following tables list the recommended torques applied for general applications Assemblies Torque value (Nm / lbf.ft) at assembly of the compressor. Wheel nuts 120 (88.56) +/- 15 Bolts, axle/beams 205 (151.29) +/- 20 For hexagon screws and nuts with strength grade 8.8 Bolts, towbar/axle... -
Page 57: Settings Of Shutdown Switches And Safety Valves
SETTINGS OF SHUTDOWN SWITCHES AND SAFETY VALVES Designation XA(S) 137 DD - XA(S) 137 DDG - XAHS 107 DD - XA(S) 300 DD7 XA(S) 300 DD7G XAHS 250 DD7 Engine oil pressure bar(e) Engine oil temperature °C °F Compressor temperature °C... -
Page 58: Compressor/Engine/Generator Specifications
COMPRESSOR/ENGINE/GENERATOR SPECIFICATIONS REFERENCE CONDITIONS Designation XA(S) 137 DD - XA(S) 137 DDG - XAHS 107 DD - XA(S) 300 DD7 XA(S) 300 DD7G XAHS 250 DD7 230/400 V (3 phase) Absolute inlet pressure bar(e) 14.5 14.5 14.5 Relative air humidity Air inlet temperature °C... -
Page 59: Limitations
LIMITATIONS Designation XA(S) 137 DD - XA(S) 137 DDG - XAHS 107 DD - XA(S) 300 DD7 XA(S) 300 DD7G XAHS 250 DD7 230/400 V (3 phase) Minimum effective receiver pressure bar(e) Maximum effective receiver pressure, compressor bar(e) 13.5 unloaded... - Page 60 Performance data Max. allowable working pressure as a function of altitude and ambient temperature. TEMPERATURE IN °F TEMPERATURE IN °F TEMPERATURE IN °F 6000 6000 6000 16.405 16.405 16.405 5000 5000 5000 07 bar(e) 102 psi 13.124 13.124 13.124 4000 4000 4000 07 bar(e)
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Page 61: Performance Data
PERFORMANCE DATA At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated. Designation XA(S) 137 DD - XA(S) 137 DDG - XAHS 107 DD - XA(S) 300 DD7 XA(S) 300 DD7G XAHS 250 DD7 230/400 V (3 phase) - Page 62 Fuel consumption Designation XA(S) 137 DD - XA(S) 137 DDG - XAHS 107 DD - XA(S) 300 DD7 XA(S) 300 DD7G XAHS 250 DD7 230/400 V (3 phase) at 100% FAD kg/h 11.6 11.6 lb/h 25.6 25.6 at 75% FAD...
- Page 63 Designation XA(S) 137 DD - XA(S) 137 DDG - XAHS 107 DD - XA(S) 300 DD7 XA(S) 300 DD7G XAHS 250 DD7 230/400 V (3 phase) Typical oil content of compressed air mg/m < 5 < 5 < 5 oz/10 <...
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Page 64: Design Data
Number of compression stages Engine Designation Designation XA(S) 137 DD - XA(S) 300 DD7 XA(S) 137 DD - XA(S) 300 DD7 XA(S) 137 DDG - XA(S) 300 DD7G XA(S) 137 DDG - XA(S) 300 DD7G XAHS 107 DD - XAHS 250 DD7... - Page 65 Unit Unit dimensions Designation with brakes towbar XA(S) 137 DD - XA(S) 300 DD7 XA(S) 137 DDG - XA(S) 300 DD7G fixed adjustable XAHS 107 DD - XAHS 250 DD7 Length 3768 4278 Capacity of compressor oil 148.3 168.4 system US gal 3.43...
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Page 66: Design Data For Generator
DESIGN DATA FOR GENERATOR Alternator Electrical power circuit Designation Designation 230/400V (3 phase) Standard IEC 34-1 Rated continuous active power COP Make MECC ALTE Rated power factor (lagging) Model TR-2 ---/2 Rated continuous apparent power 3ph COP Rated output Rated voltage 3ph line to line Degree of protection Rated current 3ph Insulation... -
Page 67: Data Plate
Data plate Company code (1) (2) Product code Unit serial number Name of the manufacturer EEC or national type approval number Vehicle identification number A Maximum permitted total weight of the vehicle B Maximum permitted axle load (10) C Maximum permitted load on the towing eye (11) Model Working pressure... -
Page 68: Disposal
(for example sand, sawdust) and dispose it according the applicable 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 69: Maintenance Log
Maintenance Log Compressor ..................Customer ....................Serial number........................................Service hours Maintenance action Date By initials - 67 -... - Page 70 Notes - 68 -...
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