Atlas Copco XRHS 527 Cd C3 WUX Instruction Manual
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Atlas Copco XRHS 527 Cd C3 WUX Instruction Manual

Portable compressors
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Instruction Manual
for Portable Compressors
English
XRHS 527 Cd C3 WUX - XRHS 1150 CD4 C3 WUX
Engine CAT C13
XRVS 487 Cd C3 WUX - XRVS 1050 CD4 C3 WUX

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Summary of Contents for Atlas Copco XRHS 527 Cd C3 WUX

  • Page 1 Instruction Manual for Portable Compressors English XRHS 527 Cd C3 WUX - XRHS 1150 CD4 C3 WUX Engine CAT C13 XRVS 487 Cd C3 WUX - XRVS 1050 CD4 C3 WUX...
  • Page 3 Instruction Manual for Portable Compressors XRHS 527 Cd C3 WUX - XRHS 1150 CD4 C3 WUX XRVS 487 Cd C3 WUX - XRVS 1050 CD4 C3 WUX Original instructions Printed matter N° 9829 3014 99 ATLAS COPCO - PORTABLE ENERGY DIVISION www.atlascopco.com...
  • 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.

  • Page 5: Table Of Contents

    Table of contents Preface 4.5.1 Battery switch ........36 4.5.2 Control panel ......... 36 Please read the following instructions carefully 4.5.3 Overview icons ........38 before starting to use your compressor. Safety precautions ........7 4.5.4 Possible views........40 Introduction ..........7 It is a solid, safe and reliable machine, built 4.5.5 Starting...........
  • Page 6 5.8.2 Topping up the compressor oil....68 6.3.2 Replacing filter elements ....... 80 12.1 General ............. 103 5.8.3 Compressor oil and oil filter change ..69 6.3.3 Cleaning crankcase breather filter ..80 12.2 Disposal of materials........ 103 6.3.4 Maintenance Quick action fuel couplings .. Compressor Oil Flushing Procedure ..

  • 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

    13 If the warning light on the ABS module or in the residential areas. Lifting acceleration and retardation cable or safety chain. If the unit has no parking vehicle lights up, please contact Atlas Copco. shall be kept within safe limits. brake or jockey wheel, immobilize the unit by...
  • Page 10 13 Never refill fuel while the unit is running, unless - above 85 dB(A): room to be classified as a next to the valve. otherwise stated in the Atlas Copco Instruction noise-hazardous area and an obvious warning No external force may be exerted on the air outlet Book (AIB).

  • Page 11: Safety During Maintenance And Repair

    (check valves) to isolate recommended or approved by Atlas Copco or the 27 Do not use aerosol types of starting aids such as pressure systems. In addition, a warning sign machine manufacturer. Ascertain that the ether.

  • 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 XRHS 527 Cd - XRHS 1150 CD4 is a silenced, Engine Compressor oil system two-stage, oil-injected screw compressor, built for a The compressors are driven by a 6 cilinder in-line The oil is boosted by air pressure. The system has no nominal effective working pressure of 20 bar liquid-cooled diesel engine.
  • Page 15 Cooling system Bodywork Serial number The engine is provided with a liquid-cooler and The bodywork has openings for the intake and outlet intercooler and the compressor is provided with an oil of cooling air and hinged doors for maintenance and cooler.

  • Page 16: Main Parts

    Main parts - 16 -...
  • Page 17 Reference Name Reference Name Reference Name Alternator Exhaust Pipe Safety Valve AFce Air Filter Compressor Cooling Fan Towbar Air Filter Engine Fuel Cooler TSlp Temperature Sensor Low pressure Air Outlet Valve Filler Cap Fuel TShp Temperature Sensor High pressure Air Receiver Filler Cap Coolant Unloading Valve Battery...

  • Page 18: Regulating System

    REGULATING SYSTEM - 18 -...

  • Page 19: Air Flow

    AIR FLOW Air drawn through the airfilter (AFce) into the When the compressor is stopped and / or there is no compressor element (CElp CEhp) is compressed. At pressure in the system, the oil stop valve (OSV) the element outlet, compressed air and oil pass into prevents the oil from flowing back into the the air receiver/oil separator (AR/OS).
  • Page 20 The compressor is provided with a continuous If the air consumption is less than the maximum air pneumatic regulating system and a blow-off valve output, air receiver pressure increases and the (BOV) which is integrated in the unloader assembly regulating valve supplies control air to throttle valve (UA).

  • Page 21: Electric System

    ELECTRIC SYSTEM 9822 0963 40 - C13 HP) - 21 -...
  • Page 22 Reference Name Reference Name Spare I/O (female contacts) Pressure sensor, Regulating Pressure CAT engine service tool connector Pressure sensor, Oil stop valve pressure Fuse 10A, main Pressure sensor, Interstage pressure Circuit breaker 10A, Engine Resistor, 120 Ohm CAN J1939 Circuit breaker 10A, Engine Resistor, 120 Ohm CAN J1939 Circuit breaker 10A, Engine Emergency Stop...
  • Page 23 Eberspacher preheater Reference Name Fuel pump preheater Relay, Preheater Hydronic heater Timer Resistor 470 Ohm Thermostat Circuit breaker 10A Fuse 10A Etherstart relay Connect to 24M in cubicle Connect to 24 VDC in power supply Connect to 19 in cubicle - 23 -...
  • Page 24 Aftercooler sensors Reference Name Connect to temperature input in cubicle default: T-IN 06 Connect to 18 in cubicle Temperature sensor, PT1000, Aftercooler temperature - 24 -...
  • Page 25 Air discharge sensors Reference Name Connect to temperature input in cubicle default: T-IN 01 Connect to 18 in cubicle Connect to voltage input in cubicle default: V-IN 04 connect to 24VDC in power supply Connect to 29 in cubicle Temperature sensor, PT1000, Air discharge temperature Pressure sensor, Air discharge pressure...
  • Page 26 Refinary equipment Reference Name Relay kit 1604 3672 01 Air Shut-off Valve Connect to digital high output in cubicle default: H-OUT 10 Connect to 19 in cubicle Connect to 24M in cubicle - 26 -...
  • Page 27 Etherstart Coldstart Reference Name Reference Name Etherstart relay Connect to relay on engine connect to D-IN07 in spare I/O box Connect to 24 VDC in power supply circuit breaker 100A - 27 -...
  • Page 28 Bleeder valve Electrical fuel pump Reference Name Relay, Refueling Pump Circuit breaker 10A Reference Name Reference Name Connect to digital high output in Connect to 19 in cubicle cubicle default: H-OUT 07 Connect to 24 in cubicle Connect to 19 in cubicle Connect to H-OUT 06 in spare I/O Bleeder Valve Refueling Pump...

  • Page 29: Markings And Information Labels

    Filler cap coolant. Read the instruction manual before Read the instruction manual before Electrocution hazard. starting. topping up with coolant. Atlas Copco synthetic compressor oil. Service every 24 hours. Service point. Atlas Copco mineral engine oil. Warning! Part under pressure. Circuit breaker.

  • Page 30: Operating Instructions

    Operating instructions PARKING INSTRUCTIONS WAGON PARKING, TOWING AND LIFTING INSTRUCTIONS Safety precautions The operator is expected to apply all relevant Safety precautions. Attention Before putting the compressor in to use, check the brake system as described in section Brake shoe adjustment. After the first 100 km travel: Uncouple vehicle.

  • Page 31: Towing Instructions Wagon

    TOWING INSTRUCTIONS WAGON TOWBAR LEVELLING WAGON 10˚ 10˚ When equipped with ABS: The towbar of the wagon is equipped with an Before towing the compressor, ensure adjustable spring loaded levelling device. that the towing equipment of the vehicle  Before moving the unit without connecting the matches the towing eye.

  • Page 32: Lifting Instructions

    LIFTING INSTRUCTIONS INTERNAL LIGHTING PREHEATER (OPTION) Before performing any maintenance jobs always switch off the preheater and remove the fuse or disconnect the heater from the battery. Please be aware that the preheater unit is still “live” with the battery switch in “OFF”...

  • Page 33: Operations Overview

    OPERATIONS OVERVIEW General  When no button is pressed the display will return It is possible to override a fault shut-down by briefly to its default mode - normal time display. switching the heater off and then on again.  When setting the time, holding the buttons (2) or (3) pressed, the time will change more rapidly.

  • Page 34: Before Starting

    Setting pre-settings BEFORE STARTING  By pressing button (1) once, twice or three times 4. Remove the air receiver drain plug (1), see figure, you will select pre-set time 1, 2 or 3. and open the valve to drain possible condensate. ...
  • Page 35 9. Clogged air filter(s) will be indicated on the display of the control panel, see section Fault codes. 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.

  • Page 36: Starting / Stopping

    STARTING / STOPPING CONTROL PANEL Safety precautions Do not disconnect power supply to control box in any way when the control box is switched on. This will cause memory loss. Do not switch off the circuit breaker when the control box is switched on. This will cause memory loss.
  • Page 37 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.

  • Page 38: 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 39 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.

  • Page 40: 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 41: 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 READY TO START The instrument panel will now perform a selftest; the following display will be shown and the controller is initialized: 1286h...
  • Page 42 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 43 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 WARMING UP ENGINE CRANKING ENGINE RESTING 13˚C 40˚C 0RPM 800RPM 120s 25˚C 324RPM 300s 1286h...
  • Page 44 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 4.6bar 1286h 1200RPM 2.9 bar Active Buttons Active Buttons Stop Button...
  • Page 45 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 PREPARING TO LOAD BUILDING UP VESSEL PRESSURE LOADED 18.6 1286h...

  • Page 46: Stopping

    During operation STOPPING After pressing the STOP button the display will show: The doors must be closed during operation and may be opened for short periods for inspection and adjustments only. MAIN VIEW MAIN VIEW ENGINE COOLING DOWN Be aware not to touch hot parts when the ENGINE COOLING DOWN door is open.

  • Page 47: 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 48: Diesel Particulate Filter Regeneration

    DIESEL PARTICULATE FILTER AUTOMATIC DPF REGENERATION REGENERATION (DEFAULT) If Enter is pressed within 10 seconds then the When the Diesel Particle Filter regeneration process In specific cases, when the engine speed is constant at controller will allow the DPF regeneration to be is kept at its default ‘AUTOMATIC’...

  • Page 49: 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 85% exhaust temperature is not allowed, it might be engine does not get sufficient possibility to When no DPF regeneration is forced a warning alarm necessary to inhibit DPF regeneration.
  • Page 50 Regeneration Needed icon will disappear (engine electronics are powered down).. 7130 PLEASE FORCE DPF REGENERATION ! 7110 LOAD PREVENTION - HIGH DPF SOOT LO... Contact Atlas Copco for further actions Required Action: Required Action: to be taken.  Acknowledge the ‘PLEASE FORCE DPF ...

  • Page 51: 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 52: Settings

    SETTINGS For buttons to be used see “Control Panel” Set Language Press the SETTINGS VIEW button. Acknowledge an Alarm As long as there is an alarm icon in the middle of the bottom part of the view, all active acknowledged / un- ...
  • Page 53 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’ ...

  • Page 54: 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 55 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 56 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...

  • Page 57: Emergency Stop

    EMERGENCY STOP The emergency stop button is only to be used in emergency situations; not for stopping procedures. When an emergency stop button (1) is pressed, power to all outputs is terminated, by the emergency stop itself (hardware) as well as by the software. When the emergency stop button (1) is pressed the operator can unlock the emergency stop by turning it counterclockwise.

  • Page 58: Specific Start Procedure

    SPECIFIC START PROCEDURE After cleaning /draining the fuel tanks, the system is filled with air. Before starting the engine operate the fuelpump on the fuelfilter to fill the fuelsystem. Loosen the vent screw (1) on the fuel filter. Operate the hand pump (2) at the filter until fuel comes out of the bore for the vent screw, and air is completely removed from the fuel...

  • Page 59: 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. - 59 -...

  • Page 60: Preventive Maintenance Schedule

    3002 6071 00 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.
  • Page 61 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 60) start-up Empty air filter vacuator valves Check engine oil level (if necessary top up) Check compressor oil level (if necessary top up) Check coolant level Check/Fill fuel level (3)
  • Page 62 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 61) start-up Replace engine oil filter (2) Replace fuel (pre)filters (6) Replace fan belt Clean flow restrictor in oil scavenge line Grease hinges Check engine protective devices...
  • Page 63 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 64 Daily 50 km Every Every Every Yearly Maintenance schedule (km) after initial 500 km 1000 km 2000 km (continuation of page 63) start-up Check tyre pressure Check torque of wheel nuts Check coupling head Check height of adjusting facility Grease coupling head, tow bar bearings at the housing of the overrun brake Check brake system (if installed) and adjust if necessary Oil or grease brake lever and moving parts such as bolts and joints...

  • Page 65: Oil Specifications

    OIL SPECIFICATIONS It is strongly recommended to use Atlas The viscosity grade should correspond to the ambient temperature and ISO 3448, as follows: Copco branded lubrication oils for both Type of lubricant Compressor Engine compressor and engine. between -25°C (-13°F) and -10°C (14°F) PAROIL S between -10°C (14°F) and +30°C (86°F) PAROIL S...

  • Page 66: Engine Oil

    ENGINE OIL PAROIL from Atlas Copco is the ONLY oil tested PAROIL contains high quality anti-oxidants to PAROIL E xtra is a Synthetic ultra high performance and approved for use in all engines built into Atlas control deposits, sludge and contaminants that tend to diesel engine oil with a high viscosity-index.

  • Page 67: Oil Level Check

    OIL LEVEL CHECK CHECK COMPRESSOR OIL LEVEL CHECK ENGINE OIL LEVEL Also consult the Engine Operation Manual for the oil specifications, viscosity recommendations and oil change intervals. intervals, Maintenance schedule compressor. Check engine oil level according to the instructions in the Engine Operation Manual and if necessary top up with oil.

  • Page 68: Oil And Oil Filter Change

    OIL AND OIL FILTER CHANGE TOPPING UP THE COMPRESSOR OIL ENGINE OIL AND OIL FILTER CHANGE See section Maintenance schedule compressor. 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.

  • Page 69: Compressor Oil And Oil Filter Change

    7. Stop the compressor, wait a few minutes and top up with oil until the pointer of the oil level gauge In this case, contact Atlas Copco. is in the upper part of the green area. Never add more oil. Overfilling results in oil consumption.

  • Page 70: 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 71: Coolant Specifications

    This effectively eliminates cap while coolant is hot. currently in use in Atlas Copco compressors and the problem of restricted flow through the engine generators. coolant ducts and the radiator, minimizing the risk for The system may be under pressure.

  • Page 72: Handling Parcool Eg

    PARCOOL EG is compatible with most other injury from the splash of hot coolant.  A refractometer can be ordered from Atlas Copco 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 73: 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 74: 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 75: Replacing The Coolant

    Protect the electrical and controlling and local regulations. equipment, air filters, etc. against penetration of moisture.  From the Atlas Copco Instruction book, determine the amount of PARCOOL EG required and pour Never leave spilled liquids such as fuel, into the radiator top tank.

  • Page 76: Battery Care

    When a compressor element is due for overhaul, it electrolyte. ELECTROLYTE needs to be done by Atlas Copco. This guarantees the  Refit plugs and/or cover. use of genuine parts and correct tools with care and  Place the battery in the compressor.

  • Page 77: Adjustments And Servicing Procedures

    Adjustments and servicing procedures ADJUSTMENT OF THE CONTINUOUS PNEUMATIC REGULATING SYSTEM The working pressure is determined by the tension of the spring in the regulating valve (1). 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 78: Air Filters Engine / Compressor

    3. Safety cartridge 6. Vacuator valve 4. Inspect and tighten all air intake connections. The Atlas Copco air filters are specially designed for the application. The use of non-genuine air filters may lead to severe damage of the engine and/or compressor elements.

  • Page 79: Air Receiver

    AIR RECEIVER SAFETY VALVE FUEL SYSTEM All adjustments or repairs are to be done PRIMING INSTRUCTIONS by an authorized representative of the safety valve (2) supplier, see section Fuel leaked or spilled onto hot surfaces Specific safety precautions. or electrical components can cause a fire. To help prevent possible injury, turn the “ON/OFF”...

  • Page 80: Replacing Filter Elements

    REPLACING FILTER ELEMENTS CLEANING CRANKCASE BREATHER FILTER Replacing the filter elements: 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 81: Maintenance Quick Action Fuel Couplings

    MAINTENANCE QUICK ACTION FUEL COUPLINGS Even with proper selection and installation, quick Functional test: action coupling life may be significantly reduced Operate the system at maximum operating pressure without continuing maintenance program. and check for possible malfunctions and freedom Frequency should be determined by the severity of from leaks.

  • Page 82: Brake Adjustments

    BRAKE ADJUSTMENTS BRAKE SHOE ADJUSTMENT  Check the position of the brake equalizer compensators with the parking brake applied.  Positioned at right angles to the brake rods = even play on both wheel brakes.  Re-adjust brakes if necessary. ...

  • Page 83: Brake Adjustment Wagon Without Abs

    BRAKE ADJUSTMENT WAGON WITHOUT ABS 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. 3 mm 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 84: 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 85 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 86 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.

  • Page 87: Heater Failure

    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 Contact Atlas Copco for a thorough scan Device switched off and on again too many Contact your agent. and repair.

  • Page 88: Available Options

    Available options UNDERCARRIAGE SUPPORT MOUNTED The undercarriage makes it possible to move the With the option “Support mounted” it is possible to compressor on the site with a truck to the location fix the compressor to a truck for more flexibility or to where it is needed.
  • Page 89 WHEEL CHOCKS ADDITIONAL FUELFILTER SPARK ARRESTOR For extra safe parking on slopes. In dusty environments or in situations where the fuel The certified spark arrestor is an addition to the quality is not up to the normal standard, this exhaust that makes it possible to operate the additional fuel filter gives an extra protection to the compressor in hazardous environments like refineries fuel/combustion system.
  • Page 90 PREHEATER COLD WEATHER PACKAGE INLET SHUTDOWN VALVE The preheater is a device for preheating the cooling The cold start option consists of larger batteries The inlet shut down valve is a safety device fluid before starting when operating at low and a blow off valve to be able to start the engine preventing the engine from over speeding when temperatures.
  • Page 91 ™ OILTRONIX FUELXPERT PRESSURE REGULATOR EC The OILTRONIX is an Electronic Oil Management This is a control module that regulates engine speed System for compressors providing an optimal oil and the air inlet to optimise fuel consumption injection temperature that reduces the condensation depending on the working conditions, and the output of water in the oil.
  • Page 92 FORK LIFT SLOTS AFTER-COOLER 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.

  • Page 93: 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) at 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 94: Compressor / Engine Specifications

    COMPRESSOR / ENGINE SPECIFICATIONS REFERENCE CONDITIONS Designation XRHS 527 Cd - XRHS 1150 CD6 XRVS 487 Cd - XRVS 1050 CD6 Absolute inlet pressure bar(e) 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 95: Performance Data

    PERFORMANCE DATA At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated. Designation XRHS 527 Cd - XRHS 1150 CD6 XRVS 487 Cd - XRVS 1050 CD6 Engine shaft speed, normal and maximum r/min 1800 1800 Engine shaft speed, compressor unloaded r/min 1200 1200...
  • Page 96 Designation XRHS 527 Cd - XRHS 1150 CD6 XRVS 487 Cd - XRVS 1050 CD6 Typical oil content of compressed air mg/m < 3 < 3 oz/1000 cu.ft 0.003 0.003 Engine oil consumption (maximum) 155.25 155.25 oz/h 5.48 5.48 Compressed air temperature at °C outlet valve °F...

  • Page 97: Altitude Unit Performance Curve

    ALTITUDE UNIT PERFORMANCE CURVE Max. allowable working pressure as a function altitude and ambient temperature. TEMPERATURE °F TEMPERATURE °C - 97 -...

  • Page 98: Design Data

    DESIGN DATA Compressor Designation Number of compression stages Engine Designation All units Designation All units Make Caterpillar Capacity of oil sump: Type C13 ATAAC - Initial fill Coolant Liquid US gal 9.51 Number of cylinders - Refill (max.) Bore US gal 8.98 5.12 Capacity of cooling system...
  • Page 99 Unit Compressor dimensions Designation All units Designation All units Capacity of compressor oil Length 4.05 system US gal 19.82 inch 159.45 Net capacity of air receiver Width 2.15 US gal 37.78 inch 84.64 Capacity of fuel tanks Height 2.25 wagon / tandem US gal inch 88.58...

  • Page 100: Dataplate

    Dataplate Name of the manufacturer Vehicle identification number Model Serial Number Working pressure Speed Engine power Manufacturing year - 100 -...

  • Page 101: Legislation

    Legislation PARTS, SUBJECTED TO PRESSURE EQUIPMENT DIRECTIVE 97/23/EC, CAT. II AND ABOVE Safety valve: cat. IV Designation XRHS 527 Cd - XRHS 1150 CD6 XRVS 487 Cd - XRVS 1050 CD6 Set pressure bar(e) Design temperature °C °F Air Oil separator Designation Standard Cold start equipment...

  • Page 102: 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 - 102 -...

  • Page 103: Disposal

    (for example sand, sawdust) and recyclable materials. 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 104: Maintenance Log

    Maintenance Log Compressor ..................Customer ....................Serial number........................................Service hours Maintenance action Date By initials - 104 -...
  • Page 106 www.atlascopco.com...

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