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Atlas Copco XAMS 527 Instruction Manual

Portable compressor
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Instruction Manual
for Portable Compressors
English
XAMS 527 - XAMS 1150 CD7
XATS 487 - XATS 1050 CD7
Engine CAT C9
XAHS 447 - XAHS 950 CD7
XAVS 407 - XAVS 900 CD7

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Summary of Contents for Atlas Copco XAMS 527

  • Page 1 Instruction Manual for Portable Compressors English XAMS 527 - XAMS 1150 CD7 XATS 487 - XATS 1050 CD7 Engine CAT C9 XAHS 447 - XAHS 950 CD7 XAVS 407 - XAVS 900 CD7...
  • Page 2 Portable Compressor XAMS 527 / XAMS 1150 Cd7 XATS 487 / XATS 1050 Cd7 XAHS 447 / XAHS 950 Cd7 XAVS 407 / XAVS 900 Cd7 Printed matter N° 1092 0381 48 ATLAS COPCO - PORTABLE AIR DIVISION 07/2014 www.atlascopco.com 03/2009...
  • Page 3 The manufacturer does not accept any liability for any damage arising for modifications, additions or conversions made without the manufacturer's approval in writing. Copyright 20 4, Atlas Copco Airpower n.v., Antwerp, Belgium. Any unauthorized use or copying of the contents or any part thereof is prohibited.

  • Page 4: Table Of Contents

    Instruction Manual Table of contents SAFETY PRECAUTIONS ........................7 Introduction ............................. 7 General safety precautions ........................8 Safety during transport and installation ....................9 Safety during use and operation......................10 Safety during maintenance and repair....................12 Tool applications safety ........................14 Specific safety precautions........................
  • Page 5 Instruction Manual 3.3.12 Fault codes............................59 3.3.13 Emergency stop..........................62 MAINTENANCE..........................62 Liability ..............................62 Service paks............................63 Service kits ............................63 Storage..............................63 Preventive maintenance schedule for the compressor................63 Oil specifications........................... 66 4.6.1 Synthetic compressor oil PAROIL S....................67 4.6.2 Mineral compressor oil PAROIL M....................
  • Page 6 Instruction Manual PROBLEM SOLVING ......................... 88 AVAILABLE OPTIONS ........................91 TECHNICAL SPECIFICATIONS ....................... 93 Torque values ............................93 8.1.1 General torque values ........................93 8.1.2 Critical torque values........................93 Compressor / Engine specifications....................... 95 8.2.1 Reference conditions ........................95 8.2.2 Limitations............................
  • Page 7 Instruction Manual 1092 0381 48...

  • Page 8: Safety Precautions

    Introduction The policy of Atlas Copco is to provide the users of their equipment with safe, reliable and efficient products. Factors taken into account are among others: • the intended and predictable future use of the products, and the environments in which they are expected to operate, •...

  • Page 9: General Safety Precautions

    Take necessary steps to keep unauthorized persons away from the unit and eliminate all possible sources of danger at the unit. When handling, operating, overhauling and/or performing maintenance or repair on Atlas Copco equipment, the mechanics are expected to use safe engineering practices and to observe all relevant local safety requirements and ordinances.

  • Page 10: Safety During Transport And Installation

    Instruction Manual Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of oil vapour when air is admitted. Normal ratings (pressures, temperatures, speeds, etc.) shall be durably marked.

  • Page 11: Safety During Use And Operation

    Instruction Manual . check that the wheels are secure and that the tyres are in good condition and inflated correctly, . connect the signalisation cable, check all lights and connect the pneumatic brake couplers, . attach the safety break-away cable or safety chain and emergency brake cable to the towing vehicle, .
  • Page 12 13 Never refill fuel while the unit is running, unless otherwise stated in the Atlas Copco Instruction Book (AIB). Keep fuel away from hot parts such as air outlet pipes or the engine exhaust. Do not smoke when fuelling.

  • Page 13: Safety During Maintenance And Repair

    Use only the correct tools for maintenance and repair work, and only tools which are in good condition. Parts shall only be replaced by genuine Atlas Copco replacement parts. All maintenance work, other than routine attention, shall only be undertaken when the unit is stopped. Steps shall be taken to prevent inadvertent starting.

  • Page 14: Specific Safety Precautions

    If any sound-damping material is damaged, replace it to prevent the sound pressure level from increasing. 14 Use only lubricating oils and greases recommended or approved by Atlas Copco or the machine manufacturer. Ascertain that the selected lubricants comply with all applicable safety regulations, especially with regard to explosion or fire-risk and the possibility of decomposition or generation of hazardous gases.

  • Page 15: Tool Applications Safety

    Instruction Manual Install a sign prohibiting fire, open flame and smoking at the post where batteries are being charged. When batteries are being charged, an explosive gas mixture forms in the cells and might escape through the vent holes in the plugs. Thus an explosive atmosphere may form around the battery if ventilation is poor, and can remain in and around the battery for several hours after it has been charged.
  • Page 16 Instruction Manual instructions available for the valve type. Safety valves must be frequently tested and regularly maintained. The set pressure should be periodically checked for accuracy. When fitted, the lifting device should be operated at pressures not less than 75% of the set pressure to ensure free and easy movement of internal parts.

  • Page 17: Leading Particulars

    Instruction Manual Leading particulars General description The XAMS1150 CdH is a silenced, single-stage, oil-injected screw compressor, built for a nominal effective working pressure of 8.6 bar (125 psi). • Engine The compressor is driven by a liquid-cooled diesel engine. The engine’s power is transmitted to the compressor element through a heavy-duty coupling. •...
  • Page 18 Instruction Manual • Frame and axles The compressor/engine unit is supported by rubber buffers in the frame. The standard compressor has a towbar with parking brakes. For available options see chapter 7 Available options. • Bodywork The bodywork has openings for the intake and outlet of cooling air and hinged doors for maintenance and service operations.

  • Page 19: Markings And Information Labels

    Instruction Manual Markings and information labels Dangerous outlet gases. Danger, heat flat. Electrocution hazard. Atlas Copco synthetic compressor oil. Atlas Copco mineral engine oil. Manual. Read the instruction manual before working on the battery. Reset fuse. On / off button.
  • Page 20 Instruction Manual Warning! Part under pressure. Do not stand on outlet valves. Start-Stop indication of switch. Do not run the compressor with open doors. Lifting permitted. Use diesel fuel only. 5.5 bar (80 psi) Tyre pressure. Sound power level in accordance with Directive 00/14/EEC (expressed in dB (A)). Fork lifting permitted.

  • Page 21: Main Parts

    Instruction Manual Main parts OFce FCeo AFce FCft DPar DPce FPco FFpc DPeo DPoc Reference Name Alternator AFce Air Filter (compressor element) Air Filter (engine) Air Filter Switch Air Outlet Valves Air Receiver Ambient Temperature Sensor Battery Brake Handle Cubicle for Electrical devices Compressor Element Coolant Level Switch Control Panel...
  • Page 22 Instruction Manual Reference Name Control Unit DPar Drain Plug Air Receiver DPce Drain Plug Compressor Element DPeo Drain Plug Engine Oil DPoc Drain Plug Oil Cooler Drain Plug Radiator Engine Oil Level Dipstick Engine Exhaust Pipe Emergency Stop Element Temperature Sensor Fuse FCeo Filler Cap (engine oil)

  • Page 23: Regulating System

    Instruction Manual Regulating system 2.4.1 Overview Reference Name AFce Air Filter (compr. element) Air Filter (engine) Air Filter Switch Air Outlet Valves Air Receiver Blow Off Valve BVof Bypass Valve oil filter 1092 0381 48...
  • Page 24 Instruction Manual Reference Name Coupling Cubicle for Electrical devices Compressor Element Control Unit Check Valve Drain Plug Engine Fuse FPco Filler Plug (oil compressor element) Flow Restrictor Loading Valve Minimum Pressure Valve Oil Cooler OFce Oil Filter (compressor element) Oil Level Gauge Oil Separator Oil Stop Valve Pressure Sensor...

  • Page 25: Air Flow

    Instruction Manual 2.4.2 Air flow Air drawn through the airfilter (AFce) into the compressor element (CE) is compressed. At the element outlet, compressed air and oil pass into the air receiver/oil separator (AR/OS). The check valve (CV) prevents blow-back of compressed air when the compressor is stopped. In the air receiver/oil separator (AR/OS), most of the oil is removed from the air/oil mixture.

  • Page 26: Oil System

    Instruction Manual 2.4.3 Oil system The lower part of the air receiver (AR) serves as oil tank. Air pressure forces the oil from the air receiver/oil separator (AR/OS) through the oil cooler (OC), the oil filters (OF) and the oil stop valve (OSV) to the compressor element (CE). When the compressor is stopped and / or there is no pressure in the system, the oil stop valve (OSV) prevents the oil from flowing back into the compressor element.

  • Page 27: Continuous Regulating System

    Instruction Manual 2.4.4 Continuous regulating system The compressor is provided with a continuous regulating system and a blow-off valve (BOV) which is integrated in the unloader assembly (UA). The valve is closed during operation by outlet pressure of the compressor element and opens by air receiver pressure when the compressor is stopped.
  • Page 28 Instruction Manual If the air consumption is less than the maximum air output, air receiver pressure increases and the regulating valve supplies control air to throttle valve (TV) to reduce the air output and holds air receiver pressure between the normal working pressure and the corresponding unloading pressure.

  • Page 29: Electric System

    Instruction Manual Electric system Circuit diagram (9822 0963 15 - Size 2 C9 LP) Reference Name Spare I/O Fuse 15A Battery Battery Alternator H4-5 Warning flasher lights Horn Relay Starter motor Relay Aux. starter Level Switch, Coolant level warning Level Switch, Coolant level shutdown Level sensor, Fuel level 1092 0381 48...
  • Page 30 Instruction Manual Reference Name Starter motor Compressor Control Module Engine Control Module (Caterpillar) Pressure Switch, Airfilter Pressure sensor, Vessel Pressure Pressure sensor, Regulating Pressure Emergency stop button Temperature sensor, PT1000, LP Element temperature Temperature sensor, PT1000, Ambient temperature Loading Valve 1092 0381 48...

  • Page 31: Options

    Instruction Manual Available options Aftercooler package An integral aftercooler, with water separator, is available to reduce the outlet air temperature to ambient plus 10°C and cut water content to a mere 15%. The installation includes a by-pass over de aftercooler. Aftercooler package + fine filtration For applications that demand quality air, a fine filtration unit can be specified with the aftercooler package.

  • Page 32: Operating Instructions

    Instruction Manual Operating instructions Parking, towing and lifting instructions Safety precautions The operator is expected to apply all relevant 1 Safety precautions. Attention • Before putting the compressor in to use, check the brake system as described in section 5.5.1 Brake shoe adjustment (no ABS). •...

  • Page 33: Parking Instructions

    Instruction Manual 3.1.1 Parking instructions 1. Apply parking brake by moving the lever (1) in the direction of the arrow. 2 . Wind up the urgent brake cable (6); 3 . Enlace and fix the safety chain (2) onto the towbar (3) or take the safety chain (2) away from the towabr (3); 3 .

  • Page 34: Towing Instructions

    Instruction Manual 3.1.2 Towing instructions Before towing the compressor, ensure that the towing equipment of the vehicle matches the towing eye. The height of the towing device of the vehicle must be 815 - 845 mm (31.8 - 33 in). 1.

  • Page 35: Lifting Instructions

    Instruction Manual 3.1.3 Lifting instructions To lift the compressor, use a lift truck or crane with sufficient capacity (weight: see indication on 9 Dataplate). See to it that the compressor will be lifted vertically and remains level. Lifting acceleration and retardation must be kept within safe limits (max. 2xg). Helicopter lifting is not allowed.

  • Page 36: Before Starting

    Instruction Manual Before starting Step Action Before initial start-up, prepare battery for operation if not already done. See section 4.12.3 Recharging a battery. With the compressor standing level, check the level of the engine oil. Add oil, if necessary, to the upper mark on dipstick. Also check the engine coolant level. Consult the Engine Operation Manual for the type of coolant and type and viscosity grade of the engine oil.
  • Page 37 Instruction Manual Step Action Attach the air line(s) to the closed air outlet valve(s). Connect the safety chain. No external force may be applied to the air outlet valve(s), e.g. by pulling hoses or by connecting equipment directly to the valve(s). 1092 0381 48...
  • Page 38 Instruction Manual 3.2.1 Specific start procedure Follow this start procedure when the compressor is put in operation for the first time and after running out of fuel or changing the fuel filter. Fuel prefilter • Operate the hand pump (1) at the prefilter until it is under pressure. •...

  • Page 39: Starting / Stopping

    Instruction Manual Starting / Stopping 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 40: Specific Start Procedure

    Instruction Manual BACK button Moves back one level or ignores the change. 3.3.2 Operations overview It is possible to control the compressor locally with the Control Box, remotely with the remote switch inputs located on the back of the Control Box, or with software running on a PC with a CAN interface (PC Control Mode).

  • Page 41: Overview Icons

    Instruction Manual 3.3.4 Overview icons MAIN VIEW LOADED 1286h 1300RPM 22.4bar Reference Name Compressor status Vessel pressure indication or info text Compressor info Main View Indication Measuring View Indication Settings View Indication Alarm View Indication DPF REGENERATION High Exhaust System Temperature. Means that the Diesel Particle Filter is being regenerated.
  • Page 42 Instruction Manual Reference Name DPF REGENERATION Diesel Particle Filter Regeneration Inhibited. Means that the DPF regeneration is inhibited, even if all criteria to activate a regeneration are met. OVERHAUL Initial Overhaul required. OVERHAUL Minor Overhaul required. OVERHAUL Major Overhaul required. AUTO LOAD This icon will be shown if the Auto Load functionality is enabled, or by means of a parameter setting, or by means of pressing the load button before the machine is ready to be loaded.

  • Page 43: Possible Views

    Instruction Manual 3.3.5 Possible views Main View 22.4 Measuring View MEASUREMENTS LOADED Running Hours 1286h ECU Engine rpm 1300 rpm ECU Requested Speed 1300 rpm ECU DPF Soot Load 24 % Vessel Pressure 22.4 bar HP Element Temperature 101˚C Ambient Temperature 27˚C 1286h 1300RPM...

  • Page 44: Starting

    Instruction Manual 3.3.6 Starting Switch on the battery switch. Switch the controller on by switching the Power switch to the position “ON”. The instrument panel will now perform a selftest; the following display will be shown and the controller is initialized: Xc3003 v1.00.0 (r7307)
  • Page 45 Instruction Manual MAIN VIEW PREPARING FOR START 1286h --RPM 0.0bar The machine is now ready to be started and is waiting for a start command. Active Buttons Start Button (to initiate Start command) Load Button (to activate Automatic Load) Measurement View Button Settings View Button Alarms View Button The display now shows...
  • Page 46 Instruction Manual The display now shows MAIN VIEW READING ENGINE DATA 1286h --RPM 0.0bar The engine electronics (ECU) will be powered up. As soon as communication between compressor controller and engine controller is established, the machine will preheat according to the parameters of the engine controller. MAIN VIEW ENGINE PREHEATING 1286h...
  • Page 47 Instruction Manual If 800 rpm is not reached within 30 seconds, the starting procedure is cancelled and the engine will rest for some time. (Resting time depends on cranking time). The display now shows MAIN VIEW ENGINE RESTING 120s 1286h --RPM 0.0bar Active Buttons...
  • Page 48 Instruction Manual Active Buttons Stop Button (to cancel Start command) Load Button (to activate Automatic Load) Measurement View Button Settings View Button Alarms View Button After warming up the machine is ready to be loaded and is waiting for a load command; the display shows MAIN VIEW READY TO LOAD 1286h...
  • Page 49 Instruction Manual Active Buttons Stop Button (to cancel Start command) Load Button (to cancel Load command) Measurement View Button Settings View Button Alarms View Button The engine will now run at maximum rpm, the display will show MAIN VIEW PREPARING TO LOAD 1286h 1800RPM 4.7bar...
  • Page 50 Instruction Manual Active Buttons Stop Button (to cancel Start command) Load Button (to cancel Load command) Measurement View Button Settings View Button Alarms View Button During operation The doors must be closed during operation and may be opened for short periods for inspection and adjustments only.

  • Page 51: Stopping

    Press the UP/DOWN arrows to set the requested pressure/flow. Press ENTER to confirm the new setting. Some additional control features are available from Atlas Copco, such as dual pressure switch, remote start, auto start, remote pressure setting. If interested, please consult your Atlas Copco representative for more information.
  • Page 52 Instruction Manual MAIN VIEW ENGINE COOLING DOWN 180s 1286h 1200RPM 6.0bar Active Buttons Start Button (to initiate Start command) Measurement View Button Settings View Button Alarms View Button After cooling down the engine will stop and the display will show MAIN VIEW ENGINE STOPPING 1286h...

  • Page 53: Sutdown

    Instruction Manual MAIN VIEW SHUTDOWN 2000 EMERGENCY STOP Active Buttons Measurement View Button Settings View Button Alarms View Button Enter Button (to acknowledge the shown alarm) 3.3.9 Power off Switch the controller off by switching the Power switch to the position “OFF”. The compressor is equipped with a battery switch.
  • Page 54 Instruction Manual MAIN VIEW LOADED 18.6 1286h 1424RPM 18.6bar The DPF regeneration process will continue, until the Soot Load has become as low as possible, or until the engine is stopped. When the DPF regeneration process is stopped, the HEST icon will disappear from the display. Automatic DPF Regeneration (Default) In specific cases, when the engine speed is constant at Minimum RPM, it can happen that the DPF regeneration already starts from 30% Soot Load (LSR - Low Speed Regeneration).
  • Page 55 Instruction Manual Inhibit DPF Regeneration When running in an environment where an elevated exhaust temperature is not allowed, it might be necessary to inhibit DPF regeneration. This has to be done at Service Level. The controller has now put the DPF Regeneration in a FORCED OFF mode, which is Inhibit DPF Regeneration. The compressor controller will communicate with the engine controller and the (RED) Inhibit DPF regeneration icon will appear: DPF Regeneration Inhibited...
  • Page 56 Instruction Manual DPF Regeneration needed MAIN VIEW LOADED 18.6 7130 PLEASE FORCE DPF REGENERATION ! Required Action: • Acknowledge the ‘PLEASE FORCE DPF REGENERATION !’ warning (press Enter while in the Main View). • Force DPF Regeneration, see paragraph FORCE DPF REGENERATION When DPF Regeneration is started, the DPF Regeneration Needed icon will disappear and the HEST icon will pop-up.
  • Page 57 7120 SOOT LOAD TOO HIGH - CALL ATLAS CO... As soon as the engine is stopped, the DPF Regeneration Needed icon will disappear (engine electronics are powered down). Contact Atlas Copco for further actions to be taken. Force DPF Regeneration If DPF Regeneration is Inhibited Machine is not running: Power the controller down.

  • Page 58: Settings

    Instruction Manual • Scroll down and Enter the ‘MODE’ parameter • Scroll down and Enter the ‘AUTOMATIC’ setting • Press the Back button 3 times to get back to the Main View DPF Regeneration setting will now be AUTOMATIC DPF REGENERATION. Customer Level can now select between AUTO Regeneration &...
  • Page 59 Instruction Manual • press ENTER • scroll to ‘1290 DATE/TIME’ • ENTER the Date/Time menu • scroll to the parameter you want to change • ENTER this parameter. To change the ‘RTC Month’, scroll to the preferred month and press ENTER. To change any other RTC setting, the red figure is editable.

  • Page 60: Fault Codes

    Instruction Manual • press ENTER. Now press BACK until you’re back in the Main View (or in the menu you require). Change Display Settings Press the SETTINGS VIEW button • scroll to ‘1000 GENERAL SETTINGS’ • press ENTER • scroll to ‘1310 DISPLAY BACKLIGHT’ •...
  • Page 61 Instruction Manual Alarmcode Alarmtext Failclass Trigger 1503 INITIAL OVERHAUL REQUIRED Warning 1522 MINOR OVERHAUL WITHIN ** H Warning 1523 MINOR OVERHAUL WITHIN ** D Warning 1524 MINOR OVERHAUL REQUIRED Warning 1552 MAJOR OVERHAUL WITHIN ** H Warning 1553 MAJOR OVERHAUL WITHIN ** D Warning 1554 LOAD PREVENTION - FIRE RISK...
  • Page 62 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 63: Emergency Stop

    Instruction Manual ECU - OIL TEMPERATURE ECU - ENGINE SPEED ECU - INJECTOR 1 ECU - INJECTOR 2 ECU - INJECTOR 3 ECU - INJECTOR 4 ECU - INJECTOR 5 ECU - INJECTOR 6 ECU - INJECTOR 7 ECU - INJECTOR 8 ECU - SOOT LOAD 3.3.13 Emergency stop...

  • Page 64: Service Paks

    1000 running hours. It guarantees that all necessary parts are replaced at the same time keeping down time to a minimum. The order number of the Service Paks are listed in the Atlas Copco Parts List (ASL). Use of service paks Service Paks include all genuine parts needed for normal maintenance of both compressor and engine.
  • Page 65 Fuel prefilter (3,7) Replace Replace Fuel filter (3,7) Replace Replace Engine inlet and outlet valves (3,12) Adjust Adjust Filter element from regulating valve Replace Flow restrictor in oil scavenge line Clean Inspection by Atlas Copco Service Inspection Technician 1092 0381 48...
  • Page 66 7 Replace the fuel filters regularly. Gummed or clogged filters mean fuel starvation and reduced engine performance. The quality of the fuel determines the frequency of renewal. 8 PAROIL M 9 The following part numbers can be ordered from Atlas Copco to check on inhibitors and freezing point: • 2913 0028 00 refractometer •...

  • Page 67: Oil Specifications

    Instruction Manual Oil specifications It is strongly recommended to use Atlas Copco branded lubrication oils for both compressor and engine. High-quality, mineral, hydraulic or synthesized hydrocarbon oil with rust and oxidation inhibitors and anti-foam and anti-wear properties is recommended. The viscosity grade should correspond to the ambient temperature and ISO 3448, as follows:...

  • Page 68: Synthetic Compressor Oil Paroil S

    Instruction Manual 4.6.1 Synthetic compressor oil PAROIL S Liter (US gal, IMP gal, Cu.ft) Order number 5 liter can (1.32 Us gal can, 1.1 Imp gal can, 0.18 cu.ft can) 1615 5950 00 20 liter can (5.28 Us gal can, 4.40 Imp gal can, 0.70 cu.ft can) 1615 5951 00 209 liter barrel (55.17 Us gal barrel, 45.98 Imp gal barrel, 7.31 cu.ft barrel) 1615 5952 00...

  • Page 69: Check Compressor Oil Level

    Instruction Manual 4.7.2 Check compressor oil level Check compressor oil level With the compressor standing horizontal, check the level of the compressor oil. The pointer of the oil level gauge (1) must register in the upper extremity of the green range. Add oil if necessary. Before removing the oil filler plug (2), ensure that the pressure is released by opening an air outlet valve (3).

  • Page 70: Topping Up The Compressor Oil

    Instruction Manual 4.8.2 Topping up the compressor oil Topping up compressor oil 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 71: Compressor Oil And Oil Filter Change

    When operating in high ambient temperatures, in very dusty or high humidity conditions, it is recommended to change the oil more frequently. In this case, contact Atlas Copco Run the compressor until warm. Close the outlet valve(s) (3) and stop the compressor. Wait until the pressure is released through the automatic blow-down valve.
  • Page 72 Instruction Manual Stop the compressor, wait a few minutes and top up with oil until the pointer of the oil level gauge is in the upper part of the green area. Never add more oil. Overfilling results in oil consumption. 1092 0381 48...

  • Page 73: Coolant Specifications

    Instruction Manual Coolant specifications The use of the correct coolant is important for good heat transfer and corrosion protection of liquid-cooled engines. Liquid-cooled engines are factory filled with PARCOOL EG. PARCOOL EG is an Extended Life Ethylene Glycol based coolant, offering improved heat transfer and complete corrosion protection to preserve wet liners, cylinder head, radiator etc..

  • Page 74: Coolant Check

    • Check the pH value of the coolant using a pH-measuring device. • The pH-meter can be ordered from Atlas Copco with part number 2913 0029 00. • Typical value for EG = 8.6. • If the pH-level is below 7 or above 9.5, the coolant should be replaced.

  • Page 75: Topping Up Of Coolant

    • Flush twice with clean water. Used coolant must be disposed or recycled in accordance with laws and local regulations. • From the Atlas Copco Instruction book, determine the amount of PARCOOL EG required and pour into the radiator top tank.

  • Page 76: Cleaning Coolers

    Instruction Manual 4.11 Cleaning coolers Compressor oil cooler (1), radiator (2) and intercooler (3) Keep the coolers (1), (2) and (3) clean to maintain the cooling efficiency. Service doors (4) are provided on both sides of the fan cowl to allow easy access to the fan side surface of the coolers.

  • Page 77: Electrolyte

    Instruction Manual The battery must be in operation within 2 months from being activated; if not, it needs to be recharged first. 4.12.1 Electrolyte Read the safety instructions carefully. Electrolyte in batteries is a sulphuric acid solution in distilled water. The solution must be made up before being introduced into the battery.

  • Page 78: Recharging A Battery

    • Keep the terminals and clamps tight, clean, and lightely covered with petroleum jelly. 4.13 Compressor element overhaul When a compressor element is due for overhaul, it needs to be done by Atlas Copco. This guarantees the use of genuine parts and correct tools with care and precision. 1092 0381 48...

  • Page 79: Adjustments And Servicing Procedures

    Instruction Manual 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 80: Air Filters Engine / Compressor

    Dust trap cover Safety cartridge Filter element Filter housing Vacuator valve 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. 1092 0381 48...

  • Page 81: Cleaning The Dust Trap

    Instruction Manual 5.2.2 Cleaning the dust trap Air filter To remove dust from the dust trap pinch the vacuator valve (1) several times. 5.2.3 Replacing the filter element and the safety cartridge Air filter The instructions apply to one air filter and should be repeated for both air filters engine and air filters compressor. Step Action Release the snap clips (1) and remove the dust trap cover (2).

  • Page 82: Air Receiver

    Instruction Manual Step Action A dirty safety cartridge (3) is an indication of a malfunctioning filter element. Replace the filter element and the safety cartridge at the same time. New elements should be inspected for tears and punctures before installation. The safety cartridge cannot be cleaned.

  • Page 83: Safety Valve

    Instruction Manual Safety valve All adjustments or repairs are to be done by an authorized representative of the valve supplier, see section 1.7 Specific safety precautions. Following checks must be carried out: • A check of the opening of the lifting gear, twice a year. This can be done by screwing the cap of the valve anti-clockwise.

  • Page 84: Fuel System

    Instruction Manual Fuel system Fuel filter Replacing the filter elements: Installation instructions: Step Action Drain fuel from the bowl. Remove filter (2, 3), filterelement (4) and separate bowl (2) from element (3). Apply film of gas oil to new bowl seat. Screw bowl (2) to new element (3) tightly by hand.
  • Page 85 Instruction Manual Prime the fuel system in order to fill the fuel filter. Prime the fuel system in order to purge trapped air. The fuel system should be primed under the following conditions: • Compressor is put in operation for the first time •...

  • Page 86: Brake Adjustments

    Instruction Manual Brake adjustments 5.5.1 Brake shoe adjustment (no ABS) • Tighten the adjustment nut (A) on the wheel brake with a spanner until the wheel will not rotate in the direction of travel. • Centre the brake shoes by applying the parking brake several times. •...

  • Page 87: Brake Adjustment Wagon

    Instruction Manual 5.5.2 Brake cable adjustment Brake cable adjustment Rotate those nuts to adjust brake cable. . Rotate the nuts on position ‘D’ to adjust length2, . Rotate the nuts on position ‘B’ to adjust length3, . Rotate the nuts on position ‘ ’ to adjust length1. Use 200-300 N force to pull or push the brake handle several times , then position the handle on the-not-engaged-tooth position, adjust again if necessary.

  • Page 88: Frame Maintenance And Repair

    Instruction Manual 5.5.3 Use and maintenance of axle 1. For the nuts used in U bolts, the first check must carry out half month later, and then check them every two month. 2. Check the pressure of wheels every three month . 3.

  • Page 89: Problem Solving

    Remove and inspect elements. Clean or replace, if necessary. Regulating valve (RV) defective. Have regulating valve removed and inspected by an Atlas Copco Service representative. Blow down valve stuck in open position. Check and correct as necessary. Loading valve (LV) leaking past O-ring.
  • Page 90 Regulating valve (RV) opens too late or its ball valve Have regulating valve removed and inspected by an spring is broken. Atlas Copco Service representative. Air leaks in regulating system. Check hoses and their fittings. Stop leaks; replace leaking hoses.
  • Page 91 Oil cooler clogged externally. Clean oil cooler. Refer to section 4.11 Cleaning coolers. Oil cooler clogged internally. Consult Atlas Copco. Oil filters clogged. Replace oil filters. Oil level too low. Check oil level. Top up with recommended oil if necessary.

  • Page 92: Available Options

    Instruction Manual Available options The compressor can be delivered with following options: Pressure vessel approval ASME Undercarriage Undercarriage Wagon undercarriage, Tandem undercarriage ABS brakes Skid mounted Without undercarriage Towing eye Not included Nato Towbar levelling device Road signalisation Obligatory for road approval Wheel chocks Air treatment Quality air equipment...
  • Page 93 Instruction Manual Additional literature set Special frame color Special canopy color Not included One color Two colors Packaging Not included Wooden case 1092 0381 48...

  • Page 94: Technical Specifications

    Instruction Manual Technical specifications Torque values 8.1.1 General torque values Torque values The following tables list the recommended torques applied for general applications at assembly of the compressor. For hexagon screws and nuts with strength grade 8.8 Thread size Torque value (Nm / lbf.ft) 9 (6.64) 23 (16.97) 46 (34.69...
  • Page 95 Instruction Manual Engine to frame: Assemblies Torque value (Nm / lbf.ft) Bolts, engine/support 205 (151.29) Bolts, support/buffer 46 (33.95) Bolts, buffer/frame 23 (16.97) Lifting beams to frame: Assemblies Torque value (Nm / lbf.ft) Bolts, lifting beams/yoke (M12) 125 (92.25) Bolts, lifting beams/yoke (M16) 205 (151.29) Bolts, lifting beams/A-Frames 205 (151.29)

  • Page 96: Compressor / Engine Specifications

    Instruction Manual Compressor / engine specifications 8.2.1 Reference conditions Designation XAMS 1150 XATS 1050 XAHS 950 XAVS900 Absolute inlet pressure bar(e) 14.5 14.5 14.5 14.5 Relative air humidity Air inlet temperature °C °F Nominal effective working pressure bar(e) 10.3 The inlet conditions are specified at the air inlet grating outside the canopy. 8.2.2 Limitations XAHS950...

  • Page 97: Performance Data

    Instruction Manual 8.2.3 Performance data At reference conditions, if applicable, and at normal shaft speed, unless otherwise stated. Designation XAMS 1150 XATS 1050 XAHS 950 XAVS900 Engine shaft speed, normal and r/min 1800 1800 1800 1800 maximum Engine shaft speed, compressor r/min 1300 1300...

  • Page 98: Design Data

    Instruction Manual 8.2.4 Design data Compressor element Designation Number of compression stages Engine Designation XAMS1150CD7-XATS1050CD7 XAHS950CD7 - XAVS900CD7 Make Caterpillar Type C9 ATAAC Coolant Liquid Number of cylinders Bore 4.41 Stroke 5.87 Swept volume 8.81 cu.in Output according to DIN 6271 at normal shaft speed - Load factor Capacity of oil sump:...
  • Page 99 Instruction Manual Compressor XAMS 1150 CD7 XAHS 950 CD7 Designation XATS 1050 CD7 XAVS 900 CD7 Capacity of compressor oil system US gal 21.1 21.1 Imp gal 17.6 17.6 cu.ft 2.83 2.83 Net capacity of air receiver US gal 43.3 43.3 Imp gal 36.1...

  • Page 100: Dataplate

    Instruction Manual Dataplate 1092 0381 48...

  • Page 101: Legislation

    Instruction Manual Legislation 10.1 Parts, subjected to Pressure Equipment Directive 97/23/EC, cat. II and above Safety valve: cat. IV XAMS 1150 CD XATS 1050 CD7 XAHS 950 CD7 XAVS 900 CD7 Set pressure bar(e) Design temperature °C °F 10.2 Parts, subjected to Simple Pressure Vessel Directive 87/404/EC Air Oil separator XAMS 1150 CD7...

  • Page 102: Maintenance Record

    Instruction Manual Maintance Running hour Date Contents Signature Please do maintance work in time and fill this table. 1092 0381 48...
  • Page 103 Instruction manual Runing hour Date Contents Signature Please do maintance work in time and fill this table. 1092 0381 48...

This manual is also suitable for:

Xats 487Xahs 447Xavs 407Xams 1150 cd7Xats 1050 cd7Xahs 950 cd7 ... Show all

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